...reporting back after my post 4 days ago.
It didn't work.
The night after my "fix" it rained heavily for a prolonged period of time and when I went out to the car in the morning the lamp was again full of condensation. Damn.
Not one to be easily defeated off it came again and I gave it a good looking at...this time in very bright sunlight.
I spotted something that I missed last time...2x pin holes drilled in the lower outboard corners at each end (see 1st picture).
This is a rework according to me made by the supplier to Ford-- the lamp is marked with a date (june 2016) with a paint-pen which indicates to me the date of the rework.
Also the welding of the lens to the body of the lamp appeared to be incomplete in areas--I think this is the root-cause of the problem...a supplier quality issue...the drilled holes are the half-arsed attempt to let that moisture out. Never gunna work (would love to see the 8D for that)!
So... I again got the condensation out using the same method as before. And then went on to seal the complete lamp up with black silicon (@enigma-2 we're on the same wavelength I think).
I completely sealed it all round (pics attached) and replaced the blue stickers with something more substantial.
After I had done this I took the car for a jet-wash and whilst I went easy around the lamp there was later evidence of condensation again. This could be some residual stuff from before my rework and it went away after a bit of sun.
I'm keeping an eye on this....but in any case I don't know what to do next if its still not fixed.
As an aside I relocated the rubber seal between the lamp and the screen. Having looked at it I do not believe it was designed to be fitted under-flush to the lamp/screen assy. The profile suggests it should be fitted the way I have (again a pic below). Debatable whether it looks worse than the original build...but it will certainly keep more moisture away like this.
...reporting back after my post 4 days ago. It didn't work. The night after my "fix" it rained heavily for a prolonged period of time and when I went out to the car in the morning the lamp was again full of condensation. Damn. Not one to be easily defeated off it came again and I gave it a good looking at...this time in very bright sunlight. I spotted something that I missed last time...2x pin holes drilled in the lower outboard corners at each end (see 1st picture). This is a rework according to me made by the supplier to Ford-- the lamp is marked with a date (june 2016) with a paint-pen which indicates to me the date of the rework. Also the welding of the lens to the body of the lamp appeared to be incomplete in areas--I think this is the root-cause of the problem...a supplier quality issue...the drilled holes are the half-arsed attempt to let that moisture out. Never gunna work (would love to see the 8D for that)! So... I again got the condensation out using the same method as before. And then went on to seal the complete lamp up with black silicon (@enigma-2 we're on the same wavelength I think). I completely sealed it all round (pics attached) and replaced the blue stickers with something more substantial. After I had done this I took the car for a jet-wash and whilst I went easy around the lamp there was later evidence of condensation again. This could be some residual stuff from before my rework and it went away after a bit of sun. I'm keeping an eye on this....but in any case I don't know what to do next if its still not fixed. As an aside I relocated the rubber seal between the lamp and the screen. Having looked at it I do not believe it was designed to be fitted under-flush to the lamp/screen assy. The profile suggests it should be fitted the way I have (again a pic below). Debatable whether it looks worse than the original build...but it will certainly keep more moisture away like this.
