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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Aug 23, 2017 2:15 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Well the sun is out so I should get on with some more bodywork
Attachment:
SDC13069 (1).jpg
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Oh well. Fancied doing this instead. The old parcel shelf was too small and wouldn't sit on the supports, while the vent holes looked like they had been nibbled out by a rodent. Masking tape is to prevent the edges splintering when i use the jigsaw
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SDC13070.jpg
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Just needs the edges dressing with a file and sandpaper, then check for size
Attachment:
SDC13071.jpg
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A nice snug fit


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Aug 23, 2017 2:25 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Now to mark out the vent holes. First work out where the centre of the radius is. Then space the hole centres 30mm apart
Attachment:
SDC13072.jpg
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Then drill. I've gone for 10mm diameter purely because that was the largest drill bit I can find
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SDC13074.jpg
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That's a roll of what I believe is the correct pattern vinyl. I need to borrow a hole punch to make nice holes in the vinyl, so won't be gluing the vinyl down yet, as I don't now how big the throat is in the punch
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SDC13075.jpg
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In the meantime two coats of watered down PVA brushed on to seal the underside and edges.
And time to put the kettle on


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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Aug 28, 2017 5:37 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Had a full day on stripping the underseal from under the front passenger side (NSF) inner wing
Attachment:
SDC13079.jpg
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Leading edge if the inner wing is sound, with an old repair in the bottom corner. The towing eye needs some welding. Shocker looks a bit of a shocker, no worries though as I've a full set of Monroe radial-matics on order
Attachment:
SDC13080.jpg
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Just had to dress the welding of an old repair visible just behind the track rod end, and lashings of rust converter in the area where the wheel throws stones up - visible on the right

Now the angle grinder has had an airing, this is now starting to feel a bit more like a project :D


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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Aug 28, 2017 6:59 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Well the Custardwagon has now been with me for a fortnight, and until today I have basically been faffing around, or what I like to call 'deciding which way to go with this project'.

Have decided to aim for Solid, Dependable and Presentable - a car which could be used as a daily driver, rather than trailer queen or go down the motor sport route.

One definition of a project is a series of linked tasks with a timescale and a budget.

As a starting point, advisories on the current MOT can be summarised as:
1) Rust in the floor pan but not near suspension mountings
2) Suspension components corroded but not excessively
3) Engine has a massive oil leek

It's now fairly clear that the five MAIN tasks for the Custardwagon are therefore:
1) Strip all underseal, assess for rust and weld in new metal where necessary. Apply protective coating
2) Refresh the suspension and braking systems
3) Replace rocker cover and bottom end engine gaskets and seals
4) Re-paint only the outer body panels that need it
5) Paint or powder coat wheels and replace two tyres
...Plus a good service

My first thought regarding timescale was to get it ready for Swedish Day 2018, but then I realised the MOT is also due in May, so I need to get all jobs with the exception of item 4 completed by then. I think this should be achievable with a fair wind and providing I don't find any nasty surprises

As for budget. Well so far I've spent £200 on filters, plugs, gaskets, brake shoes, shockers and paint. I expect that to rise to somewhere around £1000 - plus the purchase price of the car


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Aug 29, 2017 6:57 am 
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Joined: Sun Jan 15, 2012 4:24 pm
Posts: 2908
Location: Dunfermline
Car Model: 11 cars
Your cracking on with this custard project Greg...
It's not looking to bad under all the Sheeite ..Keep up the good work..

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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Aug 29, 2017 5:35 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Thanks Car 55, a bit of positive feedback always helps with the motivation
Couldn't face another day of stripping underseal today though. Picked up some fuel pipe and blue hylomar this morning
Attachment:
SDC13081.jpg
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So first job was to replace the caked up fuel filter (it's a wonder the car ran at all!) and where the hose goes onto the carb it was split almost right through, so new hoses fitted as well
These arrived at the end of last week
Attachment:
SDC13085.jpg
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So off with the crusty old rocker covers
Attachment:
SDC13082.jpg
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While I'm replacing the gaskets, might as well clean these up and give them some fresh paint
Mustn't forget to check the valve clearances before they go back on


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Aug 29, 2017 5:46 pm 
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Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
There's evidence of oil getting past the gaskets
Attachment:
SDC13083.jpg
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Insides aren't sludged up, which I take as a good sign. Set about the outsides with the wire brush on the drill and some 120 grade to get in the corners
Attachment:
SDC13084.jpg
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Having cleaned up the outsides it was obvious that some pilchard has over-tightened them at some time, which no doubt added to the oil leak. As these are pressed parts, it's out with the panel beating kit to carefully get them somewhere near to flat again. Then dress with a file to remove any sharp edges


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Aug 29, 2017 7:13 pm 
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Joined: Sun Mar 02, 2014 2:30 pm
Posts: 990
Location: Belgium
Car Model: C900 T16S
I can't stand custard but I like this :)
Great project so far, keep it up !


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Aug 29, 2017 8:40 pm 
Great to see another one getting some well deserved attention. If you need any manuals or gasket templates, have a look at my website saabv4.com.

I can highly recommend Victor Reinz gaskets.


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Aug 29, 2017 9:20 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
I'm quite partial to custard myself Webby, but I couldn't eat this much...
The car came with three different manuals (plus Saabs own Owners Manual), and I've just ordered a set of engine bottom end gaskets (Doh!), but thanks for the offer melle. If I need any others I'll swing by your website. Glad the Victor Reinz gaskets come with a recommendation


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Aug 31, 2017 6:59 pm 
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Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Found 2/3 of a bottle of this yesterday, left over from a previous project
Attachment:
SDC13088.jpg
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It's a mixture of phosphoric acid and zinc phosphate. Smells 'orrible put prepares bare metal for paint nicely, so the rocker covers had a de-grease with white spirit before applying the 'metal ready' and leaving 20 minutes before washing off with water, and a quick dry off with an old towel
Then the postie and a courier brought these
Attachment:
SDC13087.jpg
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It's been like christmas the last couple of weeks with all these 96 parts arriving. No sprouts though, thankfully
Then as this had to come off to get the rocker covers off, i couldn't see the point of putting it back on without a freshen up
Attachment:
SDC13089.jpg
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All this wire brushing has killed my drill. RIP cheap $20 Warehouse drill - you've done a stirling service these last 15 years

Then had a session scraping underseal from the OSF/Drivers side front inner wing. Pretty much same story as the other side, except the towing eye doesn't need surgery


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Aug 31, 2017 8:15 pm 
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Joined: Tue Aug 23, 2016 6:57 pm
Posts: 313
Car Model: Saab 95 2.3t estate
May be worth looking into electrolysis for rusty parts.. Amazing what a battery charger, a container of sorts and some soda crystals can do..

Sent from my LG-H850 using Tapatalk


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 Post subject: Re: V4 Custardwagon
PostPosted: Fri Sep 01, 2017 7:05 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
I'll have to do a bit of research into that Seb - 'cos rusty parts are something I have plenty of
This morning's special job was to get these crusty old front shockers off. Having been feeding the nuts/studs with duck oil for the last week they came off without any dramas, apart from one nut getting stuck in the socket
Attachment:
SDC13090.jpg
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Then a nice warm afternoon, so time to spray up the rocker covers. Five coats of smoooooth hammerite should be enough. Why are small flying things attracted to wet paint?
Attachment:
SDC13093.jpg
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Not perfect, but good enough for Grundisburgh (that will be lost on anyone who has never lived in suffolk). Will leave these in the airing cupboard for a couple of days to harden off
Now that the feeler guages have returned from their unauthorised leave, tomorrow morning's job is to check the valve clearances


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 Post subject: Re: V4 Custardwagon
PostPosted: Fri Sep 01, 2017 7:22 pm 
See my electrolysis set-up in this RetroRides thread.


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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Sep 04, 2017 7:41 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Good stuff melle. You've got me thinking about what I've got lying around that can be 'repurposed'

Saturday morning job was to do the valve clearances. Three of the inlets had closed down to about 5 thou. should be 14 thou and exhausts 16 thou. First time I've used feeler gauges for anything other than scraping old gaskets off in a very long time
The rocker covers have spent all weekend on the top shelf in the airing cupboard. So this morning got everything together to put them back on with the new gaskets
Attachment:
SDC13094.jpg
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Attachment:
SDC13097.jpg
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I'm not expecting this to completely cure the oil slick, but to me it makes sense to start at the top and work down. Makes the rest of the engine bay look a bit tatty now
Then the guy who services my boiler came round and we had a brew and talked about old cars for an hour or so. Followed by a trip into town
Having got the shocks off last week, decided to have a go at the front springs this afternoon
Attachment:
SDC13096.jpg
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Even with 2 sets of spring compressors, I had to unbolt the spring lower seat to get the spring out - which is OK because I'm having the whole lot out for a clean up and repaint. Both safely removed. Think I'll see if I can get hold of the proper tool before they go back on


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 05, 2017 6:36 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Found this in the box of spares on the boot of the Custardwagon. I've never heard of Brevettato carburettors
Attachment:
SDC13099.jpg
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Turns out it's Italian for patented. A Weber with 28/36 DCOD27 stamped on the side. Is this the right one for a 96?
Don't know whether it was ever fitted to this car, and if so why was it removed?
Anyone got experience of Webers on a V4?


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 05, 2017 6:45 pm 
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Put a SOC in it!
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Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
Yep, that's the one. I've recently fitted one to Rose's 96. Unfortunately all the pics are on Photobucket so my project thread is a bit hard to follow now...

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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 05, 2017 6:59 pm 
I also have one on my 96, they're great carbs because they're modular and very tunable. Beware of worn spindles (resulting in air leaks). If you need a manifold for it pm me.


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 05, 2017 7:50 pm 
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
What's the name of your project thread Al? The words may be enlightening even if the pics aren't
There was also one of these in the box melle
Attachment:
SDC13100.jpg
SDC13100.jpg [ 111.04 KiB | Viewed 5996 times ]

Or do you mean a full manifold?


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 05, 2017 8:51 pm 
You could very well use the adaptor, even if only to ascertain the carb's condition. I have a proper manifold indeed.


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