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Supacat



Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018
United Kingdom 2013 Defender 110 Puma 2.2 XS DCPU Keswick Green
Fixing Air Intake Grill so it can't fall off again
Following on from my experience - and now others who have had the same thing happen:

http://www.defender2.net/forum/topic17458-15.html

I decided not just to get a new one from the dealer and refit, even with the vehicle being very much under warranty.

Looking in the parts book it appear the thing is held on with (3) insert & (6) bush:

Click image to enlarge

but on taking mine apart I only found one of the items present and from the photo it is hard to say which as they both appear to be identical. However, I only found 3 of the pins from the back grill - so 2 have made a bid for freedom - possibly down the air intake tubing:
[URL=]
Click image to enlarge[/URL]

I decided to drill out where the tabs had been and insert bolts through c clips sitting on the wing edge of the air intake hole:

Click image to enlarge

Click image to enlarge

I had to cut down the front edge of the c clips as it was showing around the edge of the grill when refitted:

Click image to enlarge
I put a little bit of copperslip on the internal threads of each c clip but not too much that it would end up coating the air filter

Click image to enlarge

Click image to enlarge

So next job is to see if i can find those missing 2 pins :lol:

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green
Post #231742 30th Apr 2013 2:07pm
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Go Beyond



Member Since: 30 Jan 2012
Location: Headcorn, Kent
Posts: 6676
United Kingdom 
Nice mod Thumbs Up
Post #231750 30th Apr 2013 2:25pm
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farmer giles



Member Since: 09 Feb 2011
Location: worcestershire
Posts: 1299
2011 Defender 110 Puma 2.4 SW Cairns Blue
watch out supacat, someone will be asking why your rivets aren't painted
Post #231756 30th Apr 2013 2:34pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 19568
United Kingdom 
I did similar with mine only using an aftermarket air intake grille. Thumbs Up Diesel$ Live$ Matter. ⛽️🛢️👨‍🔧🧰⚙️ RED, WHITE & BOOST! 🇬🇧
Post #231757 30th Apr 2013 2:43pm
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f15hie



Member Since: 14 Feb 2013
Location: Kent
Posts: 153
England 2013 Defender 90 Puma 2.2 XS CSW Havana
Came out 1 sunday morning to find it hanging on by 1 plastic spike, thought cant be bothered to take it to dealers although only 2 months old. So, out with the drill, drilled grille where the broken spikes were, pulled the broken spike out with pliars left the plastic retainers in and with 5 self tappers secured back. Used mrs black nail varnish painted screw covers and in 15 minutes back nice and secure Thumbs Up


Click image to enlarge

Anyway why arent the rivets painted :bow:

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green
Post #231769 30th Apr 2013 3:46pm
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Lambley



Member Since: 20 Apr 2013
Location: Mid Devon
Posts: 1435
United Kingdom 2006 Defender 90 Td5 HT Java Black
Same thing happened to my old Defender, not a great design by LR.
I used a few blobs of silicone sealant to stop it coming off, never moved after that.
Post #231851 30th Apr 2013 8:34pm
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Mattyboy



Member Since: 05 Dec 2012
Location: Sudbury
Posts: 58
United Kingdom 2007 Defender 90 Puma 2.4 HT Santorini Black
great idea, don't use supper glue like i did, it still fell off and just took the paint off the wing with it! 07 Defender 90 TDCI
98 Defender 90 300 Tdi
Land Rover Freelander
MG B GT
CBR 600
AEC Matador
but no washing machine
Post #231935 1st May 2013 8:42am
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Supacat



Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018
United Kingdom 2013 Defender 110 Puma 2.2 XS DCPU Keswick Green
f15hie wrote:
Anyway why arent the rivets painted Bow down


Is that an "in" joke - which rivets are being referred to?
Post #231940 1st May 2013 8:56am
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farmer giles



Member Since: 09 Feb 2011
Location: worcestershire
Posts: 1299
2011 Defender 110 Puma 2.4 SW Cairns Blue
Supacat wrote:
f15hie wrote:
Anyway why arent the rivets painted Bow down


Is that an "in" joke - which rivets are being referred to?




shame on you!



(the rivets next to the rear wheel arch on a 110 are fixed after factory painting so don't get a lick of paint)
Post #231960 1st May 2013 9:59am
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Supacat



Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018
United Kingdom 2013 Defender 110 Puma 2.2 XS DCPU Keswick Green
OK - thanks for the explanation - slow morning here Smile

When considering whether I would use black screws or stainless bolts I did think the stainless bolts were nicely set off against the unpainted rivets...just didn't want to mention that on here Embarassed
Post #231961 1st May 2013 10:03am
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Farmer58za



Member Since: 20 Jan 2017
Location: Worcestershire
Posts: 85
South Africa 2012 Defender 90 Puma 2.2 SW Tamar Blue
Ha ha!
Today, a little "persuasion" on my TDCi air intake grill caused it to pop off. Yes, it was stuck on with the dreaded super glue!

It's Saturday so I just cleaned off the cover at the lugs and fixed it in place with Silicone and duct tape. Tomorrow, I will remove the tape and it will be just fine.

Regards
David


Mattyboy wrote:
great idea, don't use supper glue like i did, it still fell off and just took the paint off the wing with it!
 Dave's not here man...
Post #612125 25th Mar 2017 10:12pm
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Farmer58za



Member Since: 20 Jan 2017
Location: Worcestershire
Posts: 85
South Africa 2012 Defender 90 Puma 2.2 SW Tamar Blue
Re: Fixing Air Intake Grill so it can't fall off again
Supacat, that's a quality fix. You could also just drill the cover to match the air receiver plastic screw inserts and fig the receiver and the grid with the same (longer) self tapping screws.

Regards
David

Supacat wrote:
Following on from my experience - and now others who have had the same thing happen:

http://www.defender2.net/forum/topic17458-15.html

I decided not just to get a new one from the dealer and refit, even with the vehicle being very much under warranty.

Looking in the parts book it appear the thing is held on with (3) insert & (6) bush:

Click image to enlarge

but on taking mine apart I only found one of the items present and from the photo it is hard to say which as they both appear to be identical. However, I only found 3 of the pins from the back grill - so 2 have made a bid for freedom - possibly down the air intake tubing:
[URL=]
Click image to enlarge[/URL]

I decided to drill out where the tabs had been and insert bolts through c clips sitting on the wing edge of the air intake hole:

Click image to enlarge

Click image to enlarge

I had to cut down the front edge of the c clips as it was showing around the edge of the grill when refitted:

Click image to enlarge
I put a little bit of copperslip on the internal threads of each c clip but not too much that it would end up coating the air filter

Click image to enlarge

Click image to enlarge

So next job is to see if i can find those missing 2 pins Laughing


Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Mr. Green  Dave's not here man...
Post #612128 25th Mar 2017 10:17pm
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