Thank you Jim. And I think you are right on the target for a double seal idea.
I was thinking of fingering a little silicon sealer down into the holes, but I'm not sure I want silicon anywhere NEAR a surface to be painted. The Dicor might work good. I was also thinking of cold weld (JB Weld or some such), but in all likelihood it will probably be some kind of aluminum bonding epoxy. Something that really stays put, you know what I mean? Theoretically, if I get something hard and final that really bonds (like that hard green patch that a PO had applied in that roof gouge), I might even be able to retain the original factory single surface seal of the butyl tape and existing molding.
But there are a few ideas still to think through fully on this issue and I'm still on the lookout for a flexible (form-able) aluminum trim. Also, I haven't altogether discarded the plastic/vinyl molding idea for those critical rounded portions.
Most important, after molding and tape, will be to apply the right size bead and product in the form of caulking along the moldings. And from what I've learned so far, that's called Pro-flex.
