rjsurfer & Gjac,
I had seen some of your postings, but at that time I was involved with some other projects. And, RV-wise, I was still trying to learn about roof air conditioning leaks/gaskets. I learned a lot about that, and now I'm learning more and more about the insert-gutter-awning leak problems.
At this point, I'm leaning more towards a possible fix WITHOUT actually removing the IGA rail. The reason is that I too have thought much about how exactly the water comes into the inside ceiling area. I want to think that I too will find some screws that are almost completely rusted out, which would result in holes which lead directly from the gutter to the inside (at about the location/level of the ceiling/headliner).
I've yet to remove the long rubber insert because I don't dare remove the tape and risk being expose during the next rain (it's forecast for tonight and for another 3 or 4 days).
I too plan to replace ALL screws with stainless. As all of us have discovered, anywhere there might be a chance of moisture instrusion, you have to use stainless hardware. It's shameful that the manufacturers "cheap out" in this area.
I believe that I will fill the holes with "gasket maker" goop and also dab some on the new screws prior to install. Also, I will clean the caulk line above the rail and use my favorite sealant there (3M 5200). I'm also considering putting a narrow line of sealant where the new insert slips into the lower groove. This is the point that is underwater during a hard rain (which keeps the gutter full during extended periods).
Anyway, I will keep y'all posted (it'll be a while before I can get back to working on it).
Thanks for all your information.
