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Well, the Thor Customer Service Rep I contacted got back super quick. I've had great luck with all aspects of their service departments - RVs are going to have issues, no matter what, so that's a big plus. He says that my photos show standard window leak damage, and suggests letting it dry out, reasealing the top, testing for leaks, applying the fungicidal paint/sealant and then covering it up. Debating on what to use...maybe the same material as the flooring I choose. If the wood is damaged beyond this repair, however, I think changing it out may be a little out of my league. Wouldn't you need to take apart the entire front end to do that?
Jamie - If this is just a window leak, the water was getting in through some very small holes in the top exterior sealant. It looks more like not-quite-as-thick areas, as opposed to actual holes, but when I poured water on as a test some of it disappeared into the unknown. I've seen very little rain over the last 16 months, so either a little water does a whole LOT of damage, or this has been an issue for the entire time (plus the year it sat on the lot). I'm going to crawl underneath (or contort however I can) to get a better look up the wheel wells. I can feel the bottom of the plywood, so I may need to take the same action as your tech and do some sealing up in there. On your driver's side, behind the console is a great spot to check, although I had an odd dry patch right there. They are easy to remove - just take out the cupholder and you should have access to the screws holding it to the wall (if your assembly line tech used a similar method as mine, of course). Your interior leak on the passenger side is a bit confusing. I removed the frame on that side to take a peek at the construction (easy process, but you have to gain access to the frame first, which involves taking out all the surround for the bed mechanisms up at the top - picture attached). I'd check all the weep holes along the base of the frame first, just in case they are spilling over into the cab. Could you see where the water was entering - top or bottom of the window?
I'll post any updates as I progress (or regress, whatever the case may be).
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