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 Post subject: Re: DKM669K 4dr 99
PostPosted: Wed Feb 06, 2019 9:20 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Stig wrote:
Heh heh, I'll be high on adrenalin. I will not even feel the cold :geek: :roll:


Ideal Jim! hope you're ready for some fabricating!

The drivers side outer wheel tub is quite rotten, and along with the wing has had previous repairs, I think a knock had maybe started corrosion, or it had a heavier knock and a new wing fitted. either way the lower 6" of the front of the tub and the wing itself were rotten, misshaped, and had a few layers of metal in them.

ImageUntitled by ianlaw99, on Flickr

I copied the other side, leaving plenty metal for shaping the arch contour once welded in and repairing the arch started. it's easier blending it once welded in, and for some reason don't have a photo of it welded in!

Image
Untitled by ianlaw99, on Flickr

I haven't seen wings for sale for ages, and so much of this one was rotten it needed more than just little patches, it needs the whole lip and front lower 6".
For some reason I remembered reading that a 3dr rear arch from the opposite side could yield a workable repair panel for the lip at least.
This came from Saabits wonderful website and was a pittance really when you see how much metal it gives.
It's close enough to work, I've trimmed it a lot here and shaped it a little bit but it's really not bad.

ImageUntitled by ianlaw99, on Flickr

This is how little wing I'm left with after getting rid of the rot. also two worst bits of the tub edge cut out.
there's an awful lot of it missing now!
ImageUntitled by ianlaw99, on Flickr

And yes, tidying the shed is first thing on the list tomorrow!

You'll see the lower front part of the tub welded in and a mess of weld above it, the tub turned out to be quite thin with rust from the engine bay side, so a strip about 1"x2" will need to come out of this and replaced but not til the wing is fixed as I need the tub for reference to sort the wing :park:

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Rotten 1972 4dr 99
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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 09, 2019 1:19 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
So, the tub needed a few repairs before sorting the wing,

ImageUntitled by ianlaw99, on Flickr


wheel tub nearly ready for wing. I know theres surface rust but the seam is clean and bright, if its solid it's staying!

ImageUntitled by ianlaw99, on Flickr

Repair panel on and lightly buffed, bottom of this needs manipulating at front and rear, that's what I'm away to do now and hopefully make everything that's missing today/tomorrow
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 09, 2019 3:16 pm 
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Impressive work again Ian :D


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 09, 2019 3:19 pm 
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You've made a really good job on that arch Ian.. :D

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sat Feb 09, 2019 7:27 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Thanks again chaps, the arch was a bit daunting, theres around 2 foot of weld in doing that panel, just did it a tack at a time, took nearly 2 hours to get it sewn up!

got a few more wee bits done today then moved onto making the bottom of the wing, again using the other side as a guide, hopefully once it's all welded in and painted it will look alright! Here’s it mid fabrication

ImageUntitled by ianlaw99, on Flickr

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Rotten 1972 4dr 99
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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 10, 2019 3:42 pm 
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Light Pressure Turbo
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Joined: Sat Mar 03, 2007 12:34 am
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Location: Haverfordwest, Pembrokeshire, West Wales
Car Model: 1974 Silver 2dr 99 EMS
Fantastic work Ian.
Its going to be so satisfying when you finish the o/s/f and can stand back and know that corner is all solid.
That for me, would be really motivating.
Keep up the great work.

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 10, 2019 8:22 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Thanks Will, it is definitely the worst area on the car, even a few years ago I think I might have binned the shell!

between the arch being rotten and the bottom having badly repaired this wing was realistically fit for the bin, however I thought I'd have a go at sorting it as the above post says.. This is what I found after chiselling the filler out, you'll see i was still mocking up the tunnel at that stage..

ImageUntitled by ianlaw99, on Flickr

I can't criticise this because it saved the car at one point, but because the seams were all missing and the shape was funny it had to come out.

Here's another one of trying it in to try and finalise the shape.
You can see the shape was getting there but still a way to go

ImageUntitled by ianlaw99, on Flickr

A bit more shaping, some welding, some grinding, and this is how it looks now.
It will need a bit of work with the dolly and filler but not a lot. It makes sense to get everything to a state where it needs finishing/treated/epoxy primed/filled. tomorrow it will get worked a bit as welding it into the wing has pulled the seam but theres enough meat there to pull it back in, it makes the panel look like it's risen up a little

ImageUntitled by ianlaw99, on Flickr

ImageUntitled by ianlaw99, on Flickr

I'm off to open a beer.

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


Last edited by ianlaw on Sun Feb 10, 2019 8:41 pm, edited 1 time in total.

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 10, 2019 8:30 pm 
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Joined: Fri Nov 17, 2017 7:21 pm
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Location: Aberdeenshire
Car Model: 1982 99GL
Looks a very good fit Ian, I think you deserve more than one beer!


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 10, 2019 9:35 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Kraken wrote:
Looks a very good fit Ian, I think you deserve more than one beer!


I'm on my second!
wish I'd kept that lovely fresh 2dr 99!

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Rotten 1972 4dr 99
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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 10, 2019 9:48 pm 
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Location: Aberdeenshire
Car Model: 1982 99GL
ianlaw wrote:
I'm on my second!
wish I'd kept that lovely fresh 2dr 99!

Good man ;)

And don’t worry. Once you’ve finished all your repairs (admit it’s a restoration!) you’ll be way more attached to this one than that horrible old red one you had ;)


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 10, 2019 9:56 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Kraken wrote:
ianlaw wrote:
I'm on my second!
wish I'd kept that lovely fresh 2dr 99!

Good man ;)

And don’t worry. Once you’ve finished all your repairs (admit it’s a restoration!) you’ll be way more attached to this one than that horrible old red one you had ;)


Come over for a beer (bed supplied) and we'll debate those points!

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Rotten 1972 4dr 99
Amethyst 9000 CSE


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Sun Feb 10, 2019 10:20 pm 
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Location: Aberdeenshire
Car Model: 1982 99GL
ianlaw wrote:
Kraken wrote:
ianlaw wrote:
I'm on my second!
wish I'd kept that lovely fresh 2dr 99!

Good man ;)

And don’t worry. Once you’ve finished all your repairs (admit it’s a restoration!) you’ll be way more attached to this one than that horrible old red one you had ;)


Come over for a beer (bed supplied) and we'll debate those points!

Hah, you almost make that sound like a threat!

I have actually been past your way twice this week. I’ve driven through Dufftown on my way to Tomintoul and Granton on Spey. Was it you that mentioned the Charger and Thunderbird (??) in Dufftown? They look nice!

Anyway I’ll happily come through some time. No way I can turn down a beer!


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Mon Feb 11, 2019 7:05 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
You could even bring the other young lad with the white 99!!
I maybe did mention but I don't really know the folk well!

I knew this bit was ugly and the wire wheel fairly showed it!
ImageUntitled by ianlaw99, on Flickr

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Rotten 1972 4dr 99
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 Post subject: Re: DKM669K 4dr 99
PostPosted: Mon Feb 11, 2019 9:32 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Got a productive few hours on the 99 tonight, little panel but sorted out the above mess and saved the wing, again it will need a little bit of filler but once the welds are right ground off not much, the shape isn't far out.
You'll see I had to make it in 2 pieces, just to keep the shape of everything. really enjoyable little bit to sort though. still the bolt holes to do too!


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: Mon Feb 11, 2019 11:35 pm 
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There can't be many people on this planet who would have chosen to repair that wing rather than repair it. The standard of your work amazes me with such basic tools.

Great work, keep the pictures coming.

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 Post subject: Re: DKM669K 4dr 99
PostPosted: Tue Feb 12, 2019 8:30 pm 
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Location: Auchindoun, Moray, North east Scotland
Car Model: Saab 99 T16 project
Magrew wrote:
There can't be many people on this planet who would have chosen to repair that wing rather than repair it. The standard of your work amazes me with such basic tools.

Great work, keep the pictures coming.


Thanks, I appreciate that, you might actually be surprised as to how far into primary school basics the cutting out and templating with cardboard actually is. on this wing the rotten bit still had enough meat in it that I actually used it as the former and started folding the sheet of steel around it, after getting the basic shape I cut it down to a useable size, stuck it back on the car, marked round it and kept offering it up and grinding it until the panel had less than 1mm gap all the way round, then clamp, weld, grind!

This was a really simple wee patch but I think the significance of the hole can't be underestimated, I think this hole helped allow a constant supply of dampness to the lower panels all the years the car sat, that and the pine needles plugging up the drain holes helped destroy this corner of the car!
ImageUntitled by ianlaw99, on Flickr

cut out and patch made. it was good being able to avoid going into either upright part of the panel, this helped save distortion
Imagehttps://flic.kr/p/247qhze by ianlaw99, on Flickr

Tacked, note wire feed too high, great penetration but extra material on top, I had been using the welder to do a panel with bigger gaps previously, I adjusted before the rest of it was welded
Imagehttps://flic.kr/p/2eDfFcb by ianlaw99, on Flickr

Welded in and filed back, will need minor filling
ImageUntitled by ianlaw99, on FlickrImagehttps://flic.kr/p/2eDfFeL by ianlaw99, on Flickr

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


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Tue Feb 12, 2019 10:12 pm 
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Location: Aberdeenshire
Car Model: 1982 99GL
That wing is looking superb.

This thread is helping to kickstart my motivation a little bit again, so thanks for that. Getting the shed tidied up a bit again ready to get back to my welding project.

Have you got a shrinker/stretcher? If not, would you like to borrow mine?


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Tue Feb 12, 2019 10:23 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
Kraken wrote:
That wing is looking superb.

This thread is helping to kickstart my motivation a little bit again, so thanks for that. Getting the shed tidied up a bit again ready to get back to my welding project.

Have you got a shrinker/stretcher? If not, would you like to borrow mine?


You've plenty motivation! is it a big welding project?

thanks very much but Dad lent me his Frost shrinker/stretcher the other day, and it is a fantastic tool, I used it to sort the bottom of the wing, pretty sure I'll buy one :D

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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 12, 2019 11:02 pm 
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Location: Aberdeenshire
Car Model: 1982 99GL
ianlaw wrote:
You've plenty motivation! is it a big welding project?

thanks very much but Dad lent me his Frost shrinker/stretcher the other day, and it is a fantastic tool, I used it to sort the bottom of the wing, pretty sure I'll buy one :D

Very big project! I’ve done a fair bit of the rear end but not even close to the standard of your work. I still have work to do on rear arches, inner & outer sills, floor pans, some chassis repairs, inner wings.... outer wings...... headlamp surrounds.... front valance.

Then there’s work to the bonnet, bootlid, doors...

One baby step at a time though!

Yeah the Frost one is what i have too. Probably not been used for a couple of years though :!:


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 Post subject: Re: DKM669K 4dr 99
PostPosted: Wed Feb 13, 2019 9:25 am 
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Location: Aberdeen,UK
Car Model: C900S LPT Vert, 99 GL, 96 V4
That patch at the top of the wing reminds me of the " Invisible Mending " that I had to have done to my brand new school trousers when I fell off my bike after the chain slipped :roll:

Your metal patch is less visible than the patch on my trousers . . . . .great work :wink:

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