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I am planning to build an airbox out of aluminum for my engine. My plan is to fold the box into shape, and then use adhesive and rivets to join the edges. I'd like the box to be airtight, so I don't suck unfiltered air into my engine. I assume I should use rivets with a solid stem that is left in place.

Is there a structural adhesive that can act as a sealant, or a gasket-forming compound that has good adhesion?

Thanks for any suggestions,
Ian

If you are using rivets, any reason the adhesive has to be structural as opposed to standard gasket type rtv?

The rivets you describe are typically considered structural - they should be plenty strong. I'd still keep an eye on them though since vibration is good at working them loose.

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Door panel adhesive from the automotive paint store. The adhesive has both parts in the same tube and is supposed to be used with a mixing nozzle. I just squeeze (HD or so caulking gun) out what I need on a hard/clean surface and mix it. The adhesive should not be affected by fuel unlike some RTV's.


JMR

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IIRC from my old EAA days, there is (was?) a "sloshing" compound used to seal up fuel tanks that were riveted together. Any input from airframefixer, or tailwind, or ???

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Mike - Read my story at http://twinlakesseven.blogspot.com/

ngpmike, Wasn't that POR15?

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Airtight is probably over kill, it is a good idea to have a small hole in the lowest area to allow any water that reaches the box to be able to drain. 2nd aluminum is not the best material to use since it will conduct the heat from the engine bay. Plastic or fiberglass sheet stock would probably be a better option. My heater core box located in the engine bay made from aluminum conducts enough heat on a mild day to keep you warm without even passing any water through the core.
Dave W

This is the stuff that I was thinking of.

http://www.aircraftspruce.com/catalog/appages/gastanksealer.php

But, this should work, too.

http://www.aircraftspruce.com/catalog/cspages/al13063.php

Russ, I don't think POR-15 was even around when I was active in EAA. It's been a looonnngg time. I do remember a couple of brothers from Dayton, Ohio though.

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Mike - Read my story at http://twinlakesseven.blogspot.com/

3m 8115 panel bonding adhesive is very very strong and will be airtight as long as you dont miss a spot and leave a pinhole.