For some unknown-to-me reason, one of the plastic mount points for the top of our MY86 951 air box has disintegrated. I found the cheapest 'new' price to be $186 so I decided it was worth a couple hours of my time to attempt repair.
I used 15 minute epoxy and fine fiber glass cloth. First, I made a rectangular 'cup' mold from a piece of soft wood (spruce) and covered it with a nitrile glove finger (5 mil, to allow release). I then layered 8 pieces of epoxy-coated fine cloth over the wood and covered it with another nitrile glove finger (thicker, 7 mil), pulling it tightly down and chucking the wood, pinching glove finger tight, in a bench vise. As the epoxy started to harden, I 'shaped' the epoxy forcing it to a consistent shape. Using a hobby saw, I cut through the hardened cup shell to the wood, extracted the wood mold from the cup and removed the 5 mil glove finger. Having roughened up the remaining plastic around the missing mount area, I used straight epoxy to attach the cup to the top. I then added reinforcement using epoxy with cut strands of fiberglass to add mounting strength/surface area and to create a flat mount base. After finishing (filing/dremel/drilling), I coated the repair area with black 'flexible' paint (for plastic). I don't know how this repair will last but it least provides mounting where there was none before and, because of location, can be fairly 'ugly'.
Some 'fix' photos:
Peter
02-18-2019, 07:13 AM
Rusty
'Boat" (Bust out another thousand)
1986 Porsche 951 (944 Turbo)
2013 Porsche Cayenne Diesel
944 Turbo
