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PostPosted: Sat Nov 23, 2019 7:30 pm 
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Full Pressure Turbo
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Joined: Sat Jan 18, 2014 9:51 pm
Posts: 983
Location: Edinburgh
Car Model: 9-5 2.3t Arc Estate
Continuation of the fabrication of patch panels today.

I was particularly pleased with this one for the rear nearside corner of the boot floor which also extends down to the boot vent.

Image

Unfortunately I was a little careless with the wire brush on the angle grinder raking out the old seam sealer and nicked the rear lighting loom and local earth cable. A minor annoyance but easily repaired.

Image

Sent from my BKL-L09 using Tapatalk

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Saab 9-5 2.3t Arc auto estate (Big Red)
Saab 9000 2.3 CDi S auto
Saab 9-5 2.0t Airflow
Jaguar XJ6


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PostPosted: Mon Nov 25, 2019 12:46 am 
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Full Pressure Turbo
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Joined: Sat Jan 18, 2014 9:51 pm
Posts: 983
Location: Edinburgh
Car Model: 9-5 2.3t Arc Estate
I have managed to get a week working at home so I am getting some evenings in.


Magrew wrote:

1. Cut out and repair the areas of rotten metal done and all sealed and painted
2. Replace bushes in the rear swing arms done and swing arms painted
3. Replace fuel tank straps done
4. Replace flexi brake hoses managed to split rear unions at the main rigid pipes, front unions cannot be persuaded to split so some rigid pipe replacement is inevitable.
5. Break down and rebuild front and back suspension with new shocks all parts collected now but waiting for springs from powder coating, unfortunately a compressor break down prevented their return with the brake calipers
6. Refurb front subframe done
7. Fit replacement power steering pipes done
8. Fit replacement oil cooler pipes ready to go with new o-rings in hand
9. Fit replacement ACC condenser finally arrived this week
10. Fit replacement brake disc dust shields dust shields in hand but couldn't get Phase 1 fronts so planning to re-engineer later versions
11. Tidy up brakes done and look as good as new
12. Reassemble front and rear subframes and refit
13. Fit new wishbone
14. Refit interior done apart from boot
15. Prep underbody and wheel arches, paint and underseal 80% complete
16. Refit all body panels also after prep, paint and underseal
17. Install key and test drive
18. Take for MOT.
Jobs added to the plan
19. Replace rigid brake pipes where unions were so seized that they had to be cut :wall:
20. Drilling out a number of random fixings that had become very attached to the vehicle after nearly 20 years
21. Sourcing replacement items due to above. Done, thanks to Saabits and Skandix
22. Cleaning up and repairing lots of things that I had no intention in doing but now feel it needs doing since other things are going to look so tidy
23. Putting more resilient paint on the new front swing arms and the new shock absorbers because of the crap paint that is on them is already showing damage and I don't want to be doing this job again any time soon.

_________________
Saab 9-5 2.3t Arc auto estate (Big Red)
Saab 9000 2.3 CDi S auto
Saab 9-5 2.0t Airflow
Jaguar XJ6


Last edited by Magrew on Thu Dec 05, 2019 8:20 am, edited 1 time in total.

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PostPosted: Mon Nov 25, 2019 12:53 am 
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Full Pressure Turbo
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Joined: Sat Jan 18, 2014 9:51 pm
Posts: 983
Location: Edinburgh
Car Model: 9-5 2.3t Arc Estate
I unfortunately forgot to take any pictures of the progress over the weekend but this photo of the 1/4 sheet of steel I have been working off gives some idea of the extent of new metal I have put in the car.

I have also consumed 1 and a half tins of Electrox primer and a tube of tigerseal between panels to hopefully prevent any early onset of new corrosion.

Image

Sent from my BKL-L09 using Tapatalk

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Saab 9-5 2.3t Arc auto estate (Big Red)
Saab 9000 2.3 CDi S auto
Saab 9-5 2.0t Airflow
Jaguar XJ6


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PostPosted: Tue Nov 26, 2019 5:15 pm 
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Full Pressure Turbo
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Joined: Sat Oct 03, 2009 3:05 pm
Posts: 915
Location: Crewe, Cheshire
Car Model: 2002 Saab 9-5 Aero Estate
Magrew wrote:
A lot of distractions from the workshop today but I did get the calipers reassembled.

I should have taken a before photo, the transformation is quite amazing. Image

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That's a lovely job you are doing there, can I ask what you painted these callipers with, I have a set of front callipers for the 9000 primed and ready for paint, I just don't know what to paint them with currently.

I have to admire your panel making skills, it's not easy to make these complex curves and bends without specialist equipment (ask me how I know :) ). Now that I know about this thread I will be keenly following your progress - keep up the good work.

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'02' 9-5 Aero wagon
'98' 9-5 SE 2.3LPT
'98' 9000 CSE 2.0LPT
'01' 9-5 2.0L LPT
'97' Merc SL500 (oops)


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PostPosted: Wed Nov 27, 2019 7:57 am 
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Full Pressure Turbo
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Joined: Sat Jan 18, 2014 9:51 pm
Posts: 983
Location: Edinburgh
Car Model: 9-5 2.3t Arc Estate
These are powder coated. I cheated a little. :lol:

Thank you for your kind words.

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Saab 9-5 2.3t Arc auto estate (Big Red)
Saab 9000 2.3 CDi S auto
Saab 9-5 2.0t Airflow
Jaguar XJ6


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PostPosted: Thu Nov 28, 2019 5:00 pm 
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Full Pressure Turbo
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Joined: Sat Oct 03, 2009 3:05 pm
Posts: 915
Location: Crewe, Cheshire
Car Model: 2002 Saab 9-5 Aero Estate
Magrew wrote:
These are powder coated. I cheated a little. :lol:

Thank you for your kind words.


Ah OK, I have sent off for some Autotek caliper paint (brush on) for mine, they don't need to be perfect but if I can achieve a decent effect they will be fine, I like the look of yours though, nice colour too.

_________________
'02' 9-5 Aero wagon
'98' 9-5 SE 2.3LPT
'98' 9000 CSE 2.0LPT
'01' 9-5 2.0L LPT
'97' Merc SL500 (oops)


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PostPosted: Sun Dec 01, 2019 9:39 am 
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Full Pressure Turbo
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Joined: Sat Jan 18, 2014 9:51 pm
Posts: 983
Location: Edinburgh
Car Model: 9-5 2.3t Arc Estate
I made some progress again yesterday, it is difficult to make good progress when you work 360 miles from home so I try and make the most of my weekends

So yesterday I got the final two floor replacement panels in. Nothing really to show here, these are very straight forward cut and fill panels with no real bending required.

The tricky area to do however was the boot floor, this involves compound bends and recesses.

Image

I puzzled through this and decided the best approach would be to make a combination of panels and then weld them into a composite at the end. I thought this would allow better opportunity to get the double bends in and to use the recess segments to join them. It isn't going to be an invisible repair but it will certainly serve its function.

So the first step was to cut a parallel sided strip to make up the two "spars" and screw them in place. These also allowed me to establish the profile of the bowl in the areas where the floor had fallen away. As an aside the bowl was totally intact on my initial inspection but was only in place due to the underseal below and the vibration mat above. The metal had just disintegrated inbetween. I only discovered the issue because I went looking following the issues spotted on the front floorpan.

Image

With these in place I could then trace and cut the segments, each segment fitted in order of smallest to largest to offer increasing stability as the bending forces increased in persuading the new panels (read hammering) into shape.

Image

And there we have the full panel mocked up. The full panel has now been removed and has a coat of electrox was a weld through primer prior to welding up, when the screws get removed which will obviously make it look much neater.

Image

The boot floor has also been cleaned and treated with 2 coats of Hydrate 80.

As I said not an invisible repair but it is only the boot floor and I suspect it will outlast the rest of the wheel well recess. :lol:

Sent from my BKL-L09 using Tapatalk

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Saab 9-5 2.3t Arc auto estate (Big Red)
Saab 9000 2.3 CDi S auto
Saab 9-5 2.0t Airflow
Jaguar XJ6


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PostPosted: Mon Dec 02, 2019 7:02 pm 
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Full Pressure Turbo
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Joined: Sat Oct 03, 2009 3:05 pm
Posts: 915
Location: Crewe, Cheshire
Car Model: 2002 Saab 9-5 Aero Estate
That's a fair weekend's worth right there I reckon, mine had gone in a similar area but it was intending mostly across the area around and behind the stiffening section for the towbar fitment, I went over to Espin's place and cut a section out of a shell he was scrapping, it was perfect as it had never had a towbar fitted. I had the welding done by the local champ that renovated the ST1 Volvo P1800.

I think your repair will probably outlast the rest of the car, good job. Nice to see someone else using the Bilt Hamber stuff too.

I used to work away from home regularly, it's no fun and very difficult to get some life with all the travelling, good luck to you Magrew.

_________________
'02' 9-5 Aero wagon
'98' 9-5 SE 2.3LPT
'98' 9000 CSE 2.0LPT
'01' 9-5 2.0L LPT
'97' Merc SL500 (oops)


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PostPosted: Tue Dec 03, 2019 8:19 am 
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Full Pressure Turbo
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Joined: Sat Jan 18, 2014 9:51 pm
Posts: 983
Location: Edinburgh
Car Model: 9-5 2.3t Arc Estate
I did try for a wheel well tub from a local scrap yard but they wouldn't allow me to cut it out. It would have been a much neater repair.

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Saab 9-5 2.3t Arc auto estate (Big Red)
Saab 9000 2.3 CDi S auto
Saab 9-5 2.0t Airflow
Jaguar XJ6


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PostPosted: Tue Dec 03, 2019 9:23 am 
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Full Pressure Turbo
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Joined: Sat Oct 03, 2009 3:05 pm
Posts: 915
Location: Crewe, Cheshire
Car Model: 2002 Saab 9-5 Aero Estate
Magrew wrote:
I did try for a wheel well tub from a local scrap yard but they wouldn't allow me to cut it out. It would have been a much neater repair.


That's really bizarre, a scrapyard not selling their scrap, they normally make a huge profit on anything they sell outside of the scrap metal weight, can't understand their attitude.

_________________
'02' 9-5 Aero wagon
'98' 9-5 SE 2.3LPT
'98' 9000 CSE 2.0LPT
'01' 9-5 2.0L LPT
'97' Merc SL500 (oops)


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PostPosted: Tue Dec 03, 2019 12:37 pm 
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Joined: Mon Feb 19, 2007 4:12 pm
Posts: 8780
Location: Portsmouth
Car Model: 96 V4 & 9-3 Turbo-X
Mine wont leg you cut anything out with a grinder as there is risk of flamable fluids in the yard.

Wont even let you have a battery for testing electronics.

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'75 96 V4 Anniversary Restoration Project
'09 9-3 Turbo-X Wagon No. 38
B204 Haynes Roadster Project


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PostPosted: Tue Dec 03, 2019 12:49 pm 
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Joined: Sat Jan 18, 2014 9:51 pm
Posts: 983
Location: Edinburgh
Car Model: 9-5 2.3t Arc Estate
That's the response I got when I asked, safety, both a fire and an injury risk.

To be honest however when I see some of the apes in there that are wrenching or smashing things out of the cars I would argue that I am a lot safer with an angle grinder.

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Saab 9-5 2.3t Arc auto estate (Big Red)
Saab 9000 2.3 CDi S auto
Saab 9-5 2.0t Airflow
Jaguar XJ6


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PostPosted: Thu Dec 05, 2019 9:33 am 
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Full Pressure Turbo
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Joined: Sat Jan 18, 2014 9:51 pm
Posts: 983
Location: Edinburgh
Car Model: 9-5 2.3t Arc Estate
I have managed to arrange things to allow me to work from Edinburgh this week so I have managed to get a couple of evenings in the garage.

This has allowed me to progress on seam sealing and top coats of paint on repairs and to get the acoustic matting down on floor repairs.

With all that done I have reinstalled the interior. Mechanical works will progress at the weekend.

Image

Image

I have also removed the old Motorola phone installation but I have left the mount to attach a modern mobile mount to. I must get a grey press fixing for the carpet however, that black one even jumps out at me in this photo.

Spare wheel well looks a little less crude now that I have the paint and acoustic mat in. Still not a thing of beauty however but perfectly functional. :lol:

Image

Sent from my BKL-L09 using Tapatalk

_________________
Saab 9-5 2.3t Arc auto estate (Big Red)
Saab 9000 2.3 CDi S auto
Saab 9-5 2.0t Airflow
Jaguar XJ6


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