The hood secondary latch has always made contact with the airbox cover on both of my cars. Now that I have a new airbox cover, I finally decided to modify the latch lever so it doesn't make contact and cause scrapes and rusting.
In my opinion, the hole in the top of the airbox cover is either misplaced or the wrong dimensions; there should be no contact with the secondary latch lever.
There are 3 places the lever made contact with the airbox cover:
- The lowest part that is pushed by fingers to release the latch
- The vertical part just below the part that is pushed by the fingers to unlatch
- The hook of the latch makes contact with the edge of the hole in the airbox cover when closing the hood
Some time ago, I cut off the lowest part that is pushed by the fingers to release the latch, but the latch still rubbed the front of the hole in the airbox cover, causing the airbox cover to rust. There is scoring on the latch where it rubbed. The bolt holes for the latch are oval and the latch was positioned as far forward as possible, so I moved it rearward, but was still not pleased with how close it was to the hole in the airbox cover.
I first tried rebending the upper lever part of the latch, without success, so I cut a notch in the latch lever, cutting out the material that was scored from rubbing on the airbox cover.
Then, for an additional safety factor, I opened the bolt holes giving more movement of the latch. I suppose I should close the open end of the hole for added support.
Lastly, I welded a bit of the material I cut off to the latch stop, so the latch would not close all the way. Now the latch will not make contact with the airbox cover when closing the hood, but will still properly grab the support when the primary latch is released.
When I cut the notch in the lever, I also cut out a piece of the top of the lever and decided I had to weld it back on to make opening the latch a bit easier.
I will monitor the latch and see if I was successful in keeping it away from the airbox cover.
(in the pictures, the spring is removed, but will be reinstalled after media blasting and painting)