I fitted a new foam baffle to a 1.8K three weeks ago whilst doing and engine transplant from a 1.4 ,it lasted only a few days in the 1.8 engine, less than 100 miles road use before breaking up and blocking the oil pickup pipe? The oil used was Halfords Fully synth.
Years ago circa 97/98 I ran foam baffles in my old car and had no problems for 10k miles but I used Comma SynG. I wonder If the spec of the foam has changed or is it the Halfords oil ? My advise would be run without the foam baffle and mod the sump gasket as per Oily`s instruction.
Rob