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Thanks for the input and link. As suggested in some of the tech article comments, I'm thinking of trimming back the ribs on the airbox so the flange sits flush with the top of the airbox. This creates a much better surface for the adhesive to bond to. The 3M 5200 looks like an interesting alternative to epoxy.
It does look like the root of the problem is incorrect prep of the parts though; the old adhesive just peels off and there's no sign of either surface having been scuffed up prior to bonding it. The valve has been in the car at least as long as I've had it (7 years), probably much longer. I don't think I had any backfires and the valve was still in place. My guess is that the adhesive joint just degraded, maybe with lots of heat cycles and flexing over time, and gradually got worse to the point it failed
I will recheck for leaks once I've fixed it as it may well have been hiding other leaks during the smoke test.
John
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