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 Post subject: Re: DKM669K 4dr 99
PostPosted: Wed Feb 13, 2019 6:00 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1314
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Great comparison Jim! can you still get into the trousers?!

This photo means the interior has to come out as the inner wing is rotten quite a bit up at the rear.
No welding for a day or two!
ImageUntitled by ianlaw99, on Flickr

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 16, 2019 10:49 am 
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Full Pressure Turbo

Joined: Sun Mar 02, 2014 2:30 pm
Posts: 957
Location: Belgium
Car Model: C900 T16S
I don't know how I missed this one !

Fantastic work Ian, you really are an inspiration to the rest of us mere mortals :)


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 17, 2019 8:09 pm 
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Saab Nut
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Thanks Webby, really enjoying it. Used to think I preferred mechanical work but I'm quickly realising how satisfying metalwork is!

The inner wing came together not too bad, this panel had to go in past the realms of the sill and got joined in the floor, would've been easy to overlook but the sill uses the floor as the bottom part of the 'box' and with it being soft it had to come out.
Fresh steel in
ImageUntitled by ianlaw99, on Flickr

repair panel made

ImageUntitled by ianlaw99, on Flickr

Clamped, left long at the bottom for final trimming with flap wheel to blend into the contour, you'll see at this point the rear lower part of the wing still needs work, this was left loose to access the outer to inner tub weld as it's near on impossible to weld with wing in place..

ImageUntitled by ianlaw99, on Flickr

And although theres a bit of final shaping to do before primer I feel like these are a milestone couple of photos because the worst corner of the worst car I've ever owned needs no more welding!

ImageUntitled by ianlaw99, on Flickr
ImageUntitled by ianlaw99, on Flickr

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T16'D 1984 99GL
Rotten 1972 4dr 99
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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 17, 2019 10:19 pm 
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Light Pressure Turbo
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Joined: Sat Mar 03, 2007 12:34 am
Posts: 573
Location: Haverfordwest, Pembrokeshire, West Wales
Car Model: 1974 Silver 2dr 99 EMS
8) 8) 8)

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 17, 2019 10:43 pm 
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Light Pressure Turbo

Joined: Sat Jan 18, 2014 10:38 am
Posts: 404
Location: Dufftown
Car Model: 900 T16 2dr
I'm liking all the shiny new steel :-}

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 17, 2019 10:46 pm 
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Arkwright.
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Joined: Sat Jan 20, 2007 6:33 pm
Posts: 44016
Location: NETTLEHAM, LINCOLNSHIRE
Car Model: 99GL, Fiat 500 & Volvo V70
Nice work 8)

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 17, 2019 11:55 pm 
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Full Pressure Turbo

Joined: Sun Mar 02, 2014 2:30 pm
Posts: 957
Location: Belgium
Car Model: C900 T16S
Fantastic :D :D :D


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Mon Feb 18, 2019 8:53 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Thanks!!

Now, I had the interesting dilemma of moving to the back at the same side, or doing the other front inner arch.
I had probably been kidding myself that this one only needed minor therapy, but it is a scary reminder of how bad these things rot!

On the outside, lots of surface rust and a few holes

ImageUntitled by ianlaw99, on Flickr

But when you peel it open you can see there's very little left of the tower....Note where the lower arm retaining bolts go through!
ImageUntitled by ianlaw99, on Flickr


ImageUntitled by ianlaw99, on Flickr

This side is probably not as big a job as the other side, but a good illustration of what is lurking in a car that was still MOTd 4 years ago, and that corrosion has been heading that way a long long time!

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Rotten 1972 4dr 99
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 Post subject: Re: DKM669K 4dr 99
PostPosted: Mon Feb 18, 2019 9:19 pm 
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Full Pressure Turbo

Joined: Sun Mar 02, 2014 2:30 pm
Posts: 957
Location: Belgium
Car Model: C900 T16S
If I found that on my car I'd probably drink a bottle of whiskey and go to bed for a week :argh:

I guess the good news is you've got enough datum points to make the repair fairly easy, easy for a welding god such as yourself !
Good luck with the repair, I'm sure you'll make a great job of it !
I look forward to your Blue Peter moment when you show us the one you made earlier :)


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Wed Feb 20, 2019 8:45 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1314
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Webby, don't worry, I'll be having a bottle once I've welded it all up!
Thanks for the encouragement, it does help.
Part of the reason I started this thread is that I had my doubts about fixing the car, and I knew if I put photos up then I really had to push and get it done!

It would appear that the passenger side is much and such as the driver side was, there's more metal there but a lot of it is soft.
Bumper brace out and tunnel rot cut ready to come out.
Aim is to have the front end welded up by the end of the weekend!
I'm now willing to admit it is a bit of a project, not just a repair!
ImageUntitled by ianlaw99, on Flickr

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Rotten 1972 4dr 99
Amethyst 9000 CSE


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Thu Feb 21, 2019 7:42 am 
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UKS Addict
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Joined: Sun Jan 15, 2012 4:24 pm
Posts: 2863
Location: Dunfermline
Car Model: 11 cars
I'm sure you'll have it done by then Ian... Rolling by the end of the month :)

I think you should have this moved into the Restorations & Major Projects category..

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 23, 2019 9:37 am 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1314
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Car 55 wrote:
I'm sure you'll have it done by then Ian... Rolling by the end of the month :)

I think you should have this moved into the Restorations & Major Projects category..


Rolling by the end of March I hope! If the mods move it I'll not complain, I suppose it's growing arms and legs all the time..I'm still not painting it though!
I had hoped this side might just be a wee patch here and there but I've found myself back here:

I should've made opposites of the 3 parts I made for the other tower, maybe before I weld these in I'll template them and make a set or two, for the next 99...

basic stuff, grinder, marker pen, vice, clamps, jig (bearing housing)

ImageUntitled by ianlaw99, on Flickr

ImageUntitled by ianlaw99, on Flickr

I'm using 2mm steel here, and although tougher to bend it is more workable in some ways than the thinner stuff, you can stretch and fold it without distorting the whole panel.
This mornings big decision is how much of the lower part of the tunnel to leave in. it's 80% solid but soft in a few bits, it could be a tidier repair using the whole repair panel..

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T16'D 1984 99GL
Rotten 1972 4dr 99
Amethyst 9000 CSE


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 23, 2019 7:31 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1314
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
A busy day that's made the 99 slightly more solid.
One of the few panels available covers the most common cause of death of a 99, the tunnel repair, it used to be available as separate panels but now comes as one.
ImageUntitled by ianlaw99, on Flickr

It is a very strong panel and I think it can be fitted as one and welded over existing carnage.
I was well advised by Saabits that it is tricky to fit as one, I did it as one panel on the other side easily because there was so little steel left in the way, at this side I decided to cut the two apart and straighten the folded over edge.

ImageUntitled by ianlaw99, on Flickr

i actually think it will be a tidier job too. The panel needs minor reworking but is a godsend because it would take days to make with how little tools I have.

One tower repair kit knocked up and ready to go in, needs dressing, particularly the rounded bit but this will be tackled after welding as the welds will pull it a bit funny anyway

ImageUntitled by ianlaw99, on Flickr

Belly pan part of the tunnel was too soft to leave in

ImageUntitled by ianlaw99, on Flickr
ImageUntitled by ianlaw99, on Flickr

And this is where it stands tonight.
The seam part of the tunnel belly pan looks a fairly ragged shape, there's excess material in it after splitting the two repair panels but this will get shaped once the outer panel is spot welded to it

It needs a lot of work yet but hopefully a good day at it tomorrow should get this repair finished, The curve needing redefined is annoying me already!!


ImageUntitled by ianlaw99, on Flickr

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T16'D 1984 99GL
Rotten 1972 4dr 99
Amethyst 9000 CSE


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 23, 2019 9:54 pm 
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Light Pressure Turbo
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Joined: Sat Mar 03, 2007 12:34 am
Posts: 573
Location: Haverfordwest, Pembrokeshire, West Wales
Car Model: 1974 Silver 2dr 99 EMS
Fair play Ian, you're flying through this.
You'll have it in for mot in no time.
Keep up the fantastic work.

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1976 99 Ems 2dr
1974 99 Ems 2dr
1964 96 Bullnose


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 23, 2019 9:59 pm 
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Active user

Joined: Sun Aug 09, 2015 1:39 pm
Posts: 25
Location: argyll
Car Model: 900 T16s 2 door
You make that Lower Tunnel repair look easy :D .I have recently done something similar (but not as tidy ) on my 900 + it took me ages :cry: .
Keep up the good work Ian :D


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 23, 2019 10:24 pm 
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Saab Nut
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Joined: Mon May 07, 2012 6:41 pm
Posts: 1435
Location: somerset
Car Model: 93 2007 Tid vert 93 2000 vert
Ian, what can I say but WOW, you are just an inspiration
to us pure mortals, I love wood but I can see you just love metal better.
Excellent work Ian.
Kind regards Pete.

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 24, 2019 3:21 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1314
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Thanks again! this is really my first big project but I'm really enjoying it! I wish I'd learned this as a job.
when I got this car I jokingly said to a friend that it didn't need restored, it needed replaced, I'm starting to see there wasn't actually a joke in it!

Jamsaab has complete inner wing and wheel tubs for this car, if I was doing this car as a paying job I would say there would be much less time in drilling out the spot welds and replacing the complete panels, and it would be a tidier job.
If you ever pay someone to fix one this bad buy the panels!
Because this car isn't being built as a showpiece and more as a daily I'm happy with less emphasis on the aesthetic, and so far the repairs owe me less than £200 in materials.

Because I have a few other bits that need a lot of grinding and I knew that this next panel had about 20 inches of weld to dress both sides I thought I might as well do it too before I get the dust mask and goggles on for a horrible flap wheel session!!

Rotten!

ImageUntitled by ianlaw99, on Flickr

Cut out

ImageUntitled by ianlaw99, on Flickr
ImageUntitled by ianlaw99, on Flickr

remade

ImageUntitled by ianlaw99, on Flickr

Welded in, ready to start buffing off
ImageUntitled by ianlaw99, on Flickr

and from underneath. welded from the top but penetrated right through, good solid bit now, just ugly!

ImageUntitled by ianlaw99, on Flickr

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T16'D 1984 99GL
Rotten 1972 4dr 99
Amethyst 9000 CSE


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 24, 2019 5:27 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1314
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
So I've done as much as I can this weekend and the front isn't finished but maybe by the end of the week.... Massive amounts of grinding and tidying to do!
Anything that's deemed solid but still orange once the welding is done will be treated properly

Outer tunnel in, still a little bit more fabrication and welding and grinding etc needed here but you can only take out so much at a time else you lose all reference, you can see how much extra was left on the inner panel after folding down the extra edge it came with, that will round off with the grinder when I'm levelling the welds

ImageUntitled by ianlaw99, on Flickr

And one more wee repair for the day. This panel nearly got left in, and wasn't that bad, but came out to sort the bellypan.
ImageUntitled by ianlaw99, on Flickr

The shape was all there and it was solid, with a few areas of concentrated, rotten right through rust.. This is a bit of it ground out
ImageUntitled by ianlaw99, on Flickr

Because the shape was still there and the majority of the metal good I flattened a piece of copper pipe, to use as a shutter
ImageUntitled by ianlaw99, on Flickr

and then just welded up the holes from the other side. The mig welding will hardly stick to copper and it wriggled back off leaving me a solid panel
ImageUntitled by ianlaw99, on Flickr

tried in for size
ImageUntitled by ianlaw99, on Flickr

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T16'D 1984 99GL
Rotten 1972 4dr 99
Amethyst 9000 CSE


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Tue Feb 26, 2019 9:17 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1314
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
bit of grinding to do and the inner wing to sort from inside the wheel arch. You'll see the big weld across the lower crossmember, it will get blended in when I have a horrible evening dressing all these welds!

ImageUntitled by ianlaw99, on Flickr

battery tray to repair and weld in and two bits in the inner wing, small patch on front crossmember to weld, lots of grinding to do and that's the front done!

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Rotten 1972 4dr 99
Amethyst 9000 CSE


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Thu Feb 28, 2019 9:22 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1314
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Little steps... this part of the inner wing wasn't bad enough to justify the full surgery into the sill like the other side was.
The mudflap support was rotten
Again, due to limited access to the back of it to replace it i ground out all the rust and welded it back to solid

ImageUntitled by ianlaw99, on Flickr

ImageUntitled by ianlaw99, on Flickr

Made up a new bit
ImageUntitled by ianlaw99, on Flickr

ImageUntitled by ianlaw99, on Flickr

It'll all get tidied up as I move forward and mate it into the tunnel repair.

And before I came in for the night I dug out all the front arms, including a new old stock top one I picked up the other day. I don't suppose anyone knows if 95/96 ones are the same as early 99 ones, or if anyone has a new old stock passenger side early top arm?


ImageUntitled by ianlaw99, on Flickr

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Rotten 1972 4dr 99
Amethyst 9000 CSE


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