Changing the air filter today and noticed large cracks in the filter housing where it is closest to the exhaust manifold. These cracks are behind the air filter and bits of plastic are about to break off which would allow unfiltered air to be drawn into the engine. I've taped over the damage both inside and out with electrician's tape but am worried this won't stand the heat from the exhaust. New boxes seem to be like hens' teeth but if anyone can point to a source or offer advice on a repair to the existing box it would be much appreciated. I imagine this kind of plastic degradation would be common on any older Stilo 1.4.
Technical Cracks in air intake box on a Stilo 1.4 95 bhp.
- Thread starter jim cooper
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Technical Cracks in air intake box on a Stilo 1.4 95 bhp.
If you won't a strong but not maybe good looking repair I'd fibreglass it you can can fibreglass kits for £20 or so
You can also get very fine fiberglass tissue for a neater job on the outside
I'd cut a Square section around the damaged area before applying the repair
You can also get very fine fiberglass tissue for a neater job on the outside
I'd cut a Square section around the damaged area before applying the repair
If it was me, seeing as this sounds like a proper tinkering job.. 
I'd first stick some epoxy/resin/fibreglass over the crack and then before it sets, get a skinny piece of alu' sheet.. something about 0.1 - 0.2mm that you've previously cut to shape (your missus' kitchen scissors will be able to cut it) and rivet it to the box (if it' lends itself) over the epoxied crack.
Any complex/curved areas that don't lend themselves to being covered in alu' armour, ought to stand up better if the rest of the repair has something on it.
The trouble with fibreglass is that the resin stuff which sticks to every known substance in the world, apart from polypropylene-based plastics, won't want to stick to the polypropylene based plastic of the airbox... although it will only "lift" if the repair is under tension.
So covering it with something that is then riveted to the box and won't lift off with the poxy, will make the repair last longer. And Alu' sheet can be polished up a bit for a proper well-'ard "Frankenstein" look... What's not to like?
Ralf S.
I'd first stick some epoxy/resin/fibreglass over the crack and then before it sets, get a skinny piece of alu' sheet.. something about 0.1 - 0.2mm that you've previously cut to shape (your missus' kitchen scissors will be able to cut it) and rivet it to the box (if it' lends itself) over the epoxied crack. Any complex/curved areas that don't lend themselves to being covered in alu' armour, ought to stand up better if the rest of the repair has something on it.
The trouble with fibreglass is that the resin stuff which sticks to every known substance in the world, apart from polypropylene-based plastics, won't want to stick to the polypropylene based plastic of the airbox... although it will only "lift" if the repair is under tension.
So covering it with something that is then riveted to the box and won't lift off with the poxy, will make the repair last longer. And Alu' sheet can be polished up a bit for a proper well-'ard "Frankenstein" look... What's not to like?
Ralf S.
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Thanks for the suggestions. After giving it some more thought I might try a combinations of adhesive foil exhaust repair tape and high temperature silicone sealant. Some of the cracks are in awkward places/recesses but silicone might be enough to seal them on its own. I have a spare beer can handy if I go down the resin/aluminium sheet route.
