Carbon Fiber Engine cover issue...., - Alfa Romeo 4C Forums
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post #1 of 13 (permalink) Old 12-20-2016, 06:11 PM Thread Starter
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Carbon Fiber Engine cover issue....,

A few months ago I purchased one of the Squadra Sportiva CF engine covers.
One has to take the aluminum portion, the insulation, and the rubber retainers from the stock one and transfer them to the new unit.

Did that. Kind of a PITA, sore fingers when done. The studs that came assembled on the new cover are/were not long enough to fasten all of the insulation so I used some adhesive to tack the loose pieces in.

TIME PASSES This past weekend I performed my first oil change (1800 miles ). Interesting project! I went to fill the engine oil and when I started to remove the new engine cover, noted that a number of the studs had come loose from the carbon fiber..........NOT PLEASED. BTW, I had removed the engine cover a number of times while doing mods (v2 intake, fire bottle, etc) and had no issues. I also need to add that the four ball studs on the engine that the cover snaps into had been lightly lubed with scientific Hi Temp silicone grease so cover removal would not abuse or twist the cover when removing. The cover is not stiff like the stock one.

I emailed Andre and provided clear photos of the problem. He said he never saw that problem before and intimated that this happened by "not removing the oil filler cap before removing cover" !! That's the first time I 've heard of the need to do that before removing engine cover. What do you guys think about that ??

He offered a nominal refund and the suggestion that I get a high quality 2 part epoxy adhesive to repair myself, or leave it as is if it makes no noise and is stable.

Only 7 of the studs remain fastened ! Andre is receptive to resolving the problem, but for an item of this cost, I find this a marginal solution.

What do you guys think and what would you consider as resolution of this issue?
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post #2 of 13 (permalink) Old 12-20-2016, 09:37 PM
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I had the same issue with a Novitec CF cover bought through EC....I reattached the studs using glass cloth and epoxy...seems that they didn't use enough glue and not glassed in. They simply used a bit of epoxy to glue metal small studs to the CF. Whether it had something to do with not removing the oil cap or that the dealership guys yanked with too much force during an oil change hasn't been determined. IN the future I will remove the cover before taking to the dealership just in case they were responsible. When removing I pull up each corner at the attachment point rather than grabbing the outside of the cover and yanking. The ones that came loose on mine were on the side nearest the drivers side rear of car....about 4 of them. I redid the studs right before putting it in Winter hibernation so haven't had much chance to drive around to see if the problem comes back but they looked pretty solid now. Like you I found the studs nearest the back of the car were a bit on the short side and the ones nearest the front were a bit extra long....wondering if they installed them backwards. Like you I was able to make it work though.

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Last edited by RKBerta; 12-20-2016 at 09:42 PM.
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post #3 of 13 (permalink) Old 12-21-2016, 09:37 AM
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I have had the same problem with the Koshi version when I original installed the part, I haven't checked it in a few months. But your concern over long term usage of these parts is well founded, and it is my concern too. Well try epoxy then the damn things fall off too....
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post #4 of 13 (permalink) Old 12-21-2016, 01:44 PM Thread Starter
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I contacted 3m's Industrial Adhesive Division and they researched which adhesive would be the best for the conditions and materials for repairing this.

Ordered adhesive and will post when done and post followups when the glacier recedes and I hit the road again.
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post #5 of 13 (permalink) Old 12-21-2016, 01:46 PM Thread Starter
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NOT THRILLED about removing the retaining clips again....................
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post #6 of 13 (permalink) Old 12-21-2016, 04:09 PM
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Quote:
Originally Posted by IC4C View Post
I contacted 3m's Industrial Adhesive Division and they researched which adhesive would be the best for the conditions and materials for repairing this.

Ordered adhesive and will post when done and post followups when the glacier recedes and I hit the road again.
Thanks for doing this. I've a carbon fibre cover and haven't yet had your issue but that's probably only a matter of time before I do. The carbon cover is still one of the nicest visual improvements you can do to your car. It's a pity it has a couple of annoying production issues that could have been avoided with better quality control. Visually excellent but I expected better with the fastening studs. It wasn't a cheap purchase.

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post #7 of 13 (permalink) Old 12-31-2016, 12:20 AM
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Read the manual that comes with the car. It states that when removing the cover you should go to each of the four points and lift up only there and not to try to grab the entire cover and yank it off. They also say that you don't want to loosen up on the front and try to tilt it back to remove. In any case if it hangs up on the oil filler cap you will possibly bind it and cause extra stress. It may help to remove the oil filler cap first. In any case I will be careful but also will remove the cover and leave it at home when going to the dealership. First to prevent them popping the connectors again...but also I get nervous about them removing that cover and while working on the car leaving it laying around the shop with the potential of it getting knocked on the floor, or tools on it causing scratches. Those covers are pricey and definitely a very beautiful cosmetic upgrade for the coupes since you can see them through the fastback window....hate to have it damaged in some way.
I did note that both on the original cover and the new one, those rubber connectors are pretty snug so require a bit of force to loosen...especially if the engine is cold. As the temperature goes up and the rubber connectors warm, it is easier to remove the cover. I also put a bit of silicone grease on the connector to help it slide off easier.
While this may not be as much of a concern for the stock cover...it is still worth paying attention to the instructions in the manual.
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post #8 of 13 (permalink) Old 12-31-2016, 09:26 AM
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Thanks for the hint about the silicone grease, good idea.
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post #9 of 13 (permalink) Old 12-31-2016, 09:29 AM Thread Starter
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I was well versed about the removal of the engine cover and have a delicate approach to assembly and disassembly of parts I need to become accustomed to. I am a dentist and do not approach things with a hammer and crowbar. When I completed transferring the parts from the original engine cover, I put a small dab of hi temp scientific silicone grease on the ball studs! This I highly recommend !!! Made CF engine cover insertion and removal a "no stress" procedure. Had removed new engine cover a number of times since first installing it before failure occurred. Feel that the adhesive or the amount of adhesive used was insufficient when it was assembled.

Just received the 3m industrial adhesive recommended by the technical adhesive department at 3m and will be repairing over the weekend. Will post the product info once I have a chance to evaluate outcome. Also going to forward this info to Andre to inform his vendor. Andre at Squadra Sportiva has been very accomodating and the communication with him has been First Rate ! Thanks Andre !!
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post #10 of 13 (permalink) Old 12-31-2016, 01:32 PM
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Originally Posted by IC4C View Post
I was well versed about the removal of the engine cover and have a delicate approach to assembly and disassembly of parts I need to become accustomed to. I am a dentist and do not approach things with a hammer and crowbar. When I completed transferring the parts from the original engine cover, I put a small dab of hi temp scientific silicone grease on the ball studs! This I highly recommend !!! Made CF engine cover insertion and removal a "no stress" procedure. Had removed new engine cover a number of times since first installing it before failure occurred. Feel that the adhesive or the amount of adhesive used was insufficient when it was assembled.

Just received the 3m industrial adhesive recommended by the technical adhesive department at 3m and will be repairing over the weekend. Will post the product info once I have a chance to evaluate outcome. Also going to forward this info to Andre to inform his vendor. Andre at Squadra Sportiva has been very accomodating and the communication with him has been First Rate ! Thanks Andre !!
If you are going to "repair" the pegs, why not just adhese some threaded posts and then use nuts to secure insulating felt to engine cover? Would make disassembly much easier task (although why would you ever remove felt again anyway???) lol.


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