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 Post subject: Re: DKM669K 4dr 99
PostPosted: Fri Feb 01, 2019 8:28 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1293
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
So, more on the drivers side, cutting out the patched bit on the wing gave me better access to the inner/outer wheel tub seams.
The turned up lip on the front panel didn't exist and the strong triangular panel from crossmember to wheel tubs was also needing attention.

Lip tacked on and rotten bits out
ImageUntitled by ianlaw99, on Flickr

mid way,
ImageUntitled by ianlaw99, on Flickr

This is where I got to tonight, there’s still pitted bits, strangely deep and concentrated right in the corner, these are thick enough to grind out and fill with weld. I kept this wee bit all the time as a reference point. It will now allow me to sort the outer wheel tub, and then the wing. I keep telling myself this is just a quick repair to have it on the road in March but its feeling more like a project!

ImageUntitled by ianlaw99, on Flickr

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Rotten 1972 4dr 99
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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 02, 2019 8:49 am 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
PS, now have template for exhaust cutout and have left in enough metal to rework, will be nice to lose the awkward shape

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 02, 2019 8:48 pm 
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Joined: Thu May 05, 2011 4:39 pm
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
lots of little bits to do now, some awkward, some quite easy, the rest of this inner arch will have a good few hours on it.
Anything with mild surface rust I'll leave, but anything soft falls victim to the grinder.

Most of this was soft and didn't need cut out, it just fell out!

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

ImageUntitled by ianlaw99, on FlickrImageUntitled by ianlaw99, on Flickr

The wing had a previous patch, this size.
ImageUntitled by ianlaw99, on Flickr

Taking it out has helped access other repairs

underbelly seam after repairing inner wheel tub

ImageUntitled by ianlaw99, on Flickr

More than anything, the next thing I need to do is tidy the shed, get the floor clean and get an assistant to hold the dolly whist I go over all the repairs so far and flatten/straighten any of the newly welded stuff.some lines look undefined but will sharpen up
I know it's not perfect but it is just a repair! ps, sorry the photos are flashy!

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Rotten 1972 4dr 99
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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 03, 2019 11:37 am 
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Light Pressure Turbo
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Joined: Sat Mar 03, 2007 12:34 am
Posts: 571
Location: Haverfordwest, Pembrokeshire, West Wales
Car Model: 1974 Silver 2dr 99 EMS
It's all heading in the right direction Ian.
Your workmanship is very inspiring. There's loads of little bits I need to do on the EMS, mainly to tidy up previous repairs (from before I bought it I might add) ;-) and a few newer areas of corrosion. Unfortunately, I don't have a garage at home that is big enough to work in and my lockup doesn't have any power.
Keep picking away at it, seeing things taking shape must be helping keep the motivation.
Slowly, Slowly, Catchy Monkey.

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1981 99 Turbo 2dr
1976 99 Ems 2dr
1974 99 Ems 2dr
1970 99 2dr
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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 03, 2019 2:35 pm 
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Light Pressure Turbo

Joined: Sun Mar 05, 2006 10:52 am
Posts: 352
Location: Cleveland North East
Car Model: 99T
Maybe a bit late for this but..................................

https://www.machinemart.co.uk/p/115mm-d ... e-rust-re/

I am not really sure what these abrasives are made of but they really get rid of the rust, even in the pitted bits............... and leave the metal shiny shiny....... to match your shiny shiny new bits

well done for the hard work :)


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 03, 2019 3:17 pm 
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Joined: Wed Jul 28, 2010 7:30 pm
Posts: 52
Car Model: 1986 C900 carb
Really inspirational stuff, great work so far. Its definitely frighting chopping out such great lumps of car out at once. But its really coming together.


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 03, 2019 4:20 pm 
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Arkwright.
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Joined: Sat Jan 20, 2007 6:33 pm
Posts: 43747
Location: NETTLEHAM, LINCOLNSHIRE
Car Model: 99GL, Fiat 500 & Volvo V70
Top work there Ian 8)

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 03, 2019 8:57 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1293
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Thanks again for all the positive words folks!
Will, if that EMS ever gets too much please put it in my direction!
Rob, I've been on and ordered some of those, thanks! we have them at work and they're brilliant!
Mal, if only it was as solid as your one is.


The repair panel gives you most of the driveshaft hole, and in most cases that's enough... However mine was soft where the wishbone hole and the driveshaft hole come together, and I did once have a 99 collapse there whilst changing a ball joint, so I wasn't taking any chances.

This was one of the more time consuming patches I've made, and I was hopeful the panel farther up only had surface rust, not worth fully finishing until it's welded in and beat into final shape..
The lower stop was cut off to sort this

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

The welder proved the inner wing was indeed rotten at the sides of the wishbone hole, so two parts 90mm x30mm were cut out and replaced, note edges needing dressed here and the hole flange still needed final work to round it
ImageUntitled by ianlaw99, on Flickr

This left me with the steering rack hole being the only rotten bit in the drivers tub, this was a satisfying bit to make, grinder, paper, scissors, and vice, stencil taken from other side

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

Paused for a minute before getting the welder as the small part that holds the brake hose was too rotten to go back on, so the old one was used as a template
ImageUntitled by ianlaw99, on Flickr

Then a bit of welding, a bit of grinding, and this is where it's at!

I'm getting it all to this stage, then before primer I'll go round it all and do any final beating, grinding

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 03, 2019 9:44 pm 
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Light Pressure Turbo
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Joined: Sat Mar 03, 2007 12:34 am
Posts: 571
Location: Haverfordwest, Pembrokeshire, West Wales
Car Model: 1974 Silver 2dr 99 EMS
Gotta say Ian, I'm well jealous of your ability to manipulate the metal and make such good repair panels. :envy: :envy: :envy:

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1981 99 Turbo 2dr
1976 99 Ems 2dr
1974 99 Ems 2dr
1970 99 2dr
1964 96 Bullnose


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 03, 2019 9:58 pm 
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Saab Nut
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1293
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
madwelshman wrote:
Gotta say Ian, I'm well jealous of your ability to manipulate the metal and make such good repair panels. :envy: :envy: :envy:


Cheers Will but there's not much to it! just don't move on til one bit is complete..
I have a good vice, a pair of these, which are a huge godsend: https://www.frost.co.uk/brake-vice-mount-125mm.html and an anvil, sometimes a panel comes out rubbish and the easiest thing to do is just throw it away, if it's not close before it's welded in it's only going to get worse!
Ian

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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 03, 2019 10:47 pm 
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Light Pressure Turbo
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Joined: Sat Mar 03, 2007 12:34 am
Posts: 571
Location: Haverfordwest, Pembrokeshire, West Wales
Car Model: 1974 Silver 2dr 99 EMS
Cheers for the advice Ian.

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1976 99 Ems 2dr
1974 99 Ems 2dr
1970 99 2dr
1964 96 Bullnose


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Mon Feb 04, 2019 7:32 am 
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Joined: Sun Jan 15, 2012 4:24 pm
Posts: 2851
Location: Dunfermline
Car Model: 11 cars
Keep up the good work Ian, at this rate you maybe have it ready for March :)

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Mon Feb 04, 2019 7:38 am 
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Arkwright.
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Joined: Sat Jan 20, 2007 6:33 pm
Posts: 43747
Location: NETTLEHAM, LINCOLNSHIRE
Car Model: 99GL, Fiat 500 & Volvo V70
Very tidy work 8)

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Mon Feb 04, 2019 8:33 pm 
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Joined: Thu May 05, 2011 4:39 pm
Posts: 1293
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Thanks, Mike It better be ready sometime in March, I want to use it in spring!
Mal, cheers, there's a lot of finishing to be done, it's far from concours work and will be lagged in epoxy paint and underseal so hopefully that will cover all the sins! wish it was as solid as a later finnish built 2dr!

I wasn't too fussed making some of the wee bits but at the end of the day yesterday I just wasn't sure how to make this one (There's not much left of it)

ImageUntitled by ianlaw99, on Flickr

that is the wee brace on the inner wheel tub.

after thinking at work about it I cut a piece 170x 35mm ish and just folded over about a 9mm lip in the vice, I then used the ready made jig (the car) loosely vice gripped it on then hammered it into the corner and kept hitting the lip as well to stretch the flange round the corner, ignore the welds on the tunnel I've still to grind!
ImageUntitled by ianlaw99, on Flickr

then trimmed it and I ended up with this. Probably not 100% accurate but I hadn't much to go on!

ImageUntitled by ianlaw99, on Flickr

Stitched it in where the remains of the old welds were found, all in about 40 minutes work.

ImageUntitled by ianlaw99, on Flickr

will be grand when all this is doused in underseal and forgotten about!

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Rotten 1972 4dr 99
Amethyst 9000 CSE


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Mon Feb 04, 2019 10:10 pm 
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Light Pressure Turbo

Joined: Sat Jan 18, 2014 10:38 am
Posts: 402
Location: Dufftown
Car Model: 900 T16 2dr
You keep saying it's not a restoration but from what Iv'e seen so far the quality of workmanship is as good if not better than a lot of restorations that I have seen, great work, keep up the pace and standard, well done!
Dad.

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Mon Feb 04, 2019 11:09 pm 
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Joined: Wed Jan 18, 2012 5:24 pm
Posts: 6808
Location: Wigan, Lancashire
Car Model: 99L, 9000cse, 9-5s, a Panda
Ian Law senior wrote:
You keep saying it's not a restoration but from what Iv'e seen so far the quality of workmanship is as good if not better than a lot of restorations that I have seen, great work, keep up the pace and standard, well done!
Dad.

Well "dad" I've been slack jawed at some of the fabrication you've shared with us so I'll assume your praise is high praise indeed.

I wish I could weld, but then I see fabrications out of thin air and realise it wouldn't be much use. :D

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Tue Feb 05, 2019 9:26 am 
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Joined: Sun Jan 15, 2012 4:24 pm
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Ian Law senior wrote:
You keep saying it's not a restoration but from what Iv'e seen so far the quality of workmanship is as good if not better than a lot of restorations that I have seen, great work, keep up the pace and standard, well done!
Dad.


Yep, well said 'Dad'.. be as well giving it a good resto job at this stage eh, don't want to be doing similar jobs in next couple years..
He's doing it properly anyhoo..

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Tue Feb 05, 2019 11:49 am 
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Joined: Sun Apr 08, 2007 9:47 am
Posts: 3160
Location: Aberdeen,UK
Car Model: C900S LPT Vert, 99 GL, 96 V4
I just love this stuff. :geek: Exceptional skill set and patience :P

I'll be up soon to have a look at this Ian. I may even get to make a compound curvy
bit with a flange. Now there's a challenge :roll:
I am hooked now, keep it coming :wink:

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99 GL 1984
C900 16i Vert 1992
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"We are one, we are SAAB"


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Tue Feb 05, 2019 5:27 pm 
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Posts: 1293
Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Well, that is a compliment :-)
Stig wrote:
I just love this stuff. :geek: Exceptional skill set and patience :P

I'll be up soon to have a look at this Ian. I may even get to make a compound curvy
bit with a flange. Now there's a challenge :roll:
I am hooked now, keep it coming :wink:


Jim, that sounds like something very enjoyable, and it's always great to see you, however if you do come please bring a jacket as I don't have any heating at all in the shed yet and it isn't warm!!
I'm usually home all weekend and a Friday if you fancy a run out! :

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Rotten 1972 4dr 99
Amethyst 9000 CSE


Last edited by ianlaw on Wed Feb 06, 2019 8:37 am, edited 1 time in total.

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Tue Feb 05, 2019 10:22 pm 
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Joined: Sun Apr 08, 2007 9:47 am
Posts: 3160
Location: Aberdeen,UK
Car Model: C900S LPT Vert, 99 GL, 96 V4
Heh heh, I'll be high on adrenalin. I will not even feel the cold :geek: :roll:

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C900S LPT Vert 1993

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