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Projects and Restorations Building a car from scratch, restoring your pride and joy, building a track car, or starting a long term project? This is your place to document it.

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Old 04-08-2014, 03:34 AM   #11
skyegtb
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With the majority of the engine bay cleaned and de-greased it was time to remove the remaining components from there, things like the bulkhead panel, the brake servo, accelerator cable, bonnet cable, brake lines, speedo cable, fuel lines, clutch cylinder, gromets, wiring loom, fuse box etc.


















Last edited by skyegtb; 08-08-2017 at 11:27 AM.
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Old 04-08-2014, 03:35 AM   #12
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Next set of pics are of the chipping, grinding, wire brushing and knotted wheel work. I applied Phos-Kleen at various stages of the wire brushing to try to remove the worst of the rust from the pitting and like before, when I was happy that almost all of the ingrained corrosion was away I applied FE-123 to the steel that I was going to keep. After this stage it was very obvious where welding was required - plenty holes and the front cross member was of great concern but thankfully it was only the forward facing part which was corroded the rest was completely solid. The bumper supports were completely shot too - my plan was to remove them completely and make new ones. The front wings were pretty ropey on both sides but the wheel arches were surprisingly solid. Here's the pictures:








































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Old 04-08-2014, 03:36 AM   #13
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With my next 2 posts I will take this project up to date. I started the welding with the front cross member first. Same routine as before, cut the rotten bits out until good solid steel is found, shape up new steel to fit the gaps and weld it together. I treated myself to some repair panels from Saabits for the driveshaft tunnels as I knew they would need replacing and to shape the metal exactly like the originals was going to be very time consuming. The repair panels are really excellent and cover the majority of the commonly rusted bits. Luckily on this car the inner and lower sections of the driveshaft tunnels were in pretty good condition so I got away with simply welding in a few patches to repair them. Anyway, as before I will let the pictures do the talking.




























































Last edited by skyegtb; 08-08-2017 at 11:29 AM.
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Old 04-08-2014, 03:37 AM   #14
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Here is the final set of pics of the front end welding. The repairs to the windscreen scuttle panel were very time consuming but I feel the finished product was very good. I'm sure that after a skim of filler and some sanding the repairs should be virtually invisible.


















































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Old 04-08-2014, 03:38 AM   #15
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Well, that's the project up to date for now. All I did after the welding was apply a single coat of 2 pack primer to the exposed metal, then clean and de-rust some of the metal components that had been removed from the engine bay. At the moment these parts are all sitting in etch primer. The battery tray from this car was virtually non-existent through corrosion but I had a good one in my spares which I took back to bare metal - it needs a few minor welding repairs so that is on the list too. The oil cooler mounting was also knackered so a replacement will need to be sourced or fabricated (I'm sure I have one buried in my shed somewhere!). All of the fluid reservoirs were cleaned with de-greaser, washing detergent then bleach and all turned out well - the expansion tank was a challenge but bleach and the pressure washer cleaned the inside of it up almost perfectly.
Anyway, there's still a mountain of work to do, but it's looking like next time at home I should be able to get the engine bay completed, engine in, all front suspension back on and hopefully be able to move the car again! Here's the final set of pics for now.










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Old 04-08-2014, 03:39 AM   #16
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Just for fun I thought I would share some pics of my other Saab 900's, past and present. This one was my first Saab, bought in 1998: a 1989 900 T8 Special Edition. I drove this car right up until early 2007 when corrosion sadly ended the fun! The car started as factory standard with the special edition parts being the wide arches, the whale tail, the vent covers, the rear valance, the 'go faster stripes' and a leather steering wheel and gear knob. This was also intercooled and 155bhp. Over the years I made quite a number of modifications, the biggest being fitting a T16 engine, yet keeping the original K-Jetronic fuel injection system. I fitted water injection, and other tuning bits and bobs, extra fuel injectors and so on! It was a really fantastic car and what I hope to emulate with my current project.












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Old 04-08-2014, 03:39 AM   #17
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I bought my second 900 probably around 2001 as a project. This was a very rare 1985 900 T16 4 door in silver with full maroon interior and all of the gadgets, the full electric pack etc. I was sold it with the story being that the turbo had failed, but after getting the car home I found that yes, the turbo had failed, also there was almost zero compression on 3 pistons! The car was in reasonable condition so I fitted a replacement engine and repaired everything else that was broken on the car. I fitted a TE05 water cooled turbo to it and ran it like that for about 4 trouble free years when I ended up giving it away to a friend in need. Sadly the car was scrapped around 2010 again through corrosion! Anyway, this was another excellent car - definitely the comfiest 900 I have been in and pretty nippy too. Unfortunately I only have these 3 pics of the car. It needed a new radiator after the engine replacement! Also note that a previous owner had fitted the newer front bumper but kept the old rear one!

I will re-add the pictures of this car if I can find them - they were lost during my transition away from Photobucket.

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Old 04-08-2014, 03:40 AM   #18
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In early 2007 I got this one (the last one was the Green one in this project) a 1990 T16S Aero Convertible. I still have this car. It was completely standard when I bought it and was 3 speed auto. I drove it like that for the first 6 months before upgrading the suspension and fitting a JT exhaust and a few other bits like custom seats etc. The car stayed like that until 2009 when I decided to get shot of the auto-box and I fitted a manual. During the swap I fitted a lightweight flywheel, a Saab 9000 2.3 head, an upgraded TE05-16G turbo, fitted a custom 3" downpipe and did some other stuff like that. Unfortunately the first manual gearbox I fitted had issues from day one which got worse the more the car was driven, so eventually in 2012 I changed it out for the one from my old Black Saab with type 8's. At the same time I rebuilt the engine and fitted a tubular manifold, up-rated clutch and so on.
This is a truly excellent car, sadly I very rarely get the chance to drive it due to having a wife, 2 kids and a very large dog! so maybe I will have to sell it as all it is doing at present is filling up space in my garage. If I do sell I would be extremely sad to see it go... Here's some pics:
















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Old 04-08-2014, 03:41 AM   #19
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Tiny update: I managed to source a near mint replacement oil cooler housing and my father made up some new bumper irons for me. The irons just need the support tubes welded on to them, I will cut the old ones from the originals and use them.

Just 1 month until I get home to get cracking on with this project again!

Old one


New


New cooler housing

Last edited by skyegtb; 08-08-2017 at 12:04 PM.
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Old 04-08-2014, 06:18 AM   #20
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Superb work.
Thanks for sharing

I am looking forward to the next update.
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