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For full on restorations and major projects only.

Due to the number of topics within the previous Project forum we apologise for not being able to filter all topics to the relevant new forum. Please contact a member of the Admin/Mod team should you feel your topic falls within the remit of the new ''Restorations & Major Projects'' forum.
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PostPosted: Sat Jun 25, 2011 11:12 pm 
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Full Pressure Turbo

Joined: Fri Jun 16, 2006 9:26 pm
Posts: 604
Please forgive my ignorance but why would it need an IVA test?
Surely this is only required for an unregistered vehicle. (I'm assuming the 96 is still registered)
OK so you would need to declare the new engine capacity on the V5 and the 'extent' of the modifications you tell the insurance company might need some thought!
At the end of the day could it not just be a 96 with bigger engine, bigger brakes, and modified suspension?


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PostPosted: Sun Jun 26, 2011 8:03 am 
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UKS Addict
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Location: Somewhere playing with cars !!!
Car Model: Ugly speccy edna.
come on then guys - been away for a week and still no new Image :corn:

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PostPosted: Sun Jun 26, 2011 8:07 am 
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Mr Calm and Serene
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Location: Melbourne, Derbyshire
Car Model: Skoda Superb Sportline 346BHP
saab surfer wrote:
Please forgive my ignorance but why would it need an IVA test?
Surely this is only required for an unregistered vehicle. (I'm assuming the 96 is still registered)
OK so you would need to declare the new engine capacity on the V5 and the 'extent' of the modifications you tell the insurance company might need some thought!
At the end of the day could it not just be a 96 with bigger engine, bigger brakes, and modified suspension?


It's hardly retained the chassis number of the 96 by not really having the chassis of a 96 any more though has it? :wink:

Any rebuild of an old car with serious changes is going to have to get IVA tested.

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PostPosted: Sun Jun 26, 2011 10:52 pm 
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UKSaabs Trader
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Joined: Wed Apr 04, 2007 9:14 am
Posts: 2316
Location: Waltham Cross, EN8 7LX
Bitter and Twisted wrote:
come on then guys - been away for a week and still no new Image :corn:


Due to a heavy workload this week, progress on the 96 hasn't been as full on as last week. We have so far managed to source and prepare 3 of the 4 wings of the car that are replacing the damaged/corroded ones that were originally on the vehicle.

Can't get to photos at the moment but will certainly get some up soon. Now we are looking into where/how the wings will fit to the 96 and how we will be extending them to house the fatter wheels and tyres and make up for the much wider stance...

Neo Brothers

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PostPosted: Mon Jun 27, 2011 6:45 am 
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Location: West Dorset
Car Model: A mix of this and that
I thought the wings were in pretty good condition..the front wings looked like they had been recently replaced???

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PostPosted: Mon Jun 27, 2011 3:22 pm 
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Location: Waltham Cross, EN8 7LX
john-saab wrote:
I thought the wings were in pretty good condition..the front wings looked like they had been recently replaced???


The front wings were in fact fiberglass - not really what we were looking to modify.

Neo Brothers

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PostPosted: Mon Jun 27, 2011 3:50 pm 
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Location: Waltham Cross, EN8 7LX
As promised, just a couple of photos to show our progress - of the wings that we sourced, we have gone back to metal and removed any filler/paint etc.

Ready for some serious modification now...

Image

Image

Thanks
Neo Brothers

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PostPosted: Mon Jun 27, 2011 7:07 pm 
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Mr Calm and Serene
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Location: Melbourne, Derbyshire
Car Model: Skoda Superb Sportline 346BHP
Blimey, what did you use to clean up the wings, a gamma ray? :shock:

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PostPosted: Mon Jun 27, 2011 9:10 pm 
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UKS Addict
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Joined: Wed Nov 07, 2007 1:31 am
Posts: 5585
Location: Denny, Scotland
Car Model: 2002 9-5 aero wagon
ghost_walker wrote:
just thinking out loud, just trim enough of the bodies so that the sit together, cage it up, the full on climbing frame job, make some wide arches to cover up the sticky out bits and bobs your mothers brother

but this chap did it

http://www.sxoc.com/vbb/showthread.php?t=219069

might give you an idea of any pitfalls for you.

ok it was a morris minor and s13 nissan but the principal is the same



I remember that project when he first started it. Awesome.

First time I have actually looked through this. Awesome project :)

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PostPosted: Thu Jun 30, 2011 9:18 am 
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UKSaabs Trader
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Joined: Wed Apr 04, 2007 9:14 am
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Location: Waltham Cross, EN8 7LX
Hi again chaps,

Back on pace today with the project...yesterday saw the start of lightening and prep'ing the doors (and getting that :cen: underseal out of the doors!).

Image

Image

Whilst the doors are being finished today, we'll also be making a start on the widening of the wings.

Thanks,
Neo Brothers

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PostPosted: Thu Jun 30, 2011 6:37 pm 
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Location: West Dorset
Car Model: A mix of this and that
I like the furry dice!

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PostPosted: Fri Jul 01, 2011 2:04 pm 
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Location: Waltham Cross, EN8 7LX
The first door, stripped and lightened:

Image

The original untouched door weighs in at over 25kg, lightened door still needs work before we weigh it for comparison!

Image

Image

We moved onto the rear quarter and lining of the inner wheel arches yesterday...

Image

Here we had to fill the void between the 96 rear quarter and the sill of the 9-3 Sport. The quarter is not attached to any floopan as we removed it earlier:

Image

Here is the panel welded securely to the sill - grinding flat will be carried out later.

Image

Upon inspection, we had found that the rear of the quarter had rotted through so bad that we wouldn't be able to join the rear flitch/arch liner to - so we had to create our own 'lip'...

Image

Sizing up the 'new' inner liner/flitch in card first...

Image

Marked out onto sheet steel...

Image

...and accurately cut with a nibbler

Image



Image

Image

Whizzed to remove surface grease for an easier, cleaner weld.

Image

Image

Image

Image

Image

Near side internals now seam welded.

Image

Double welding (inside and outside) the inner wheel arch liners for extra strength - especially round the upper suspension turrets of the 9-3 Sport. We intend to brace the rollcage on these points at a later date.

Image

The 'excess' 9-3 Sport wheel arch liner as been trimmed back and flows neatly into the flitch of the 96. We are trying to create a smooth transition between 96 and 9-3 Sport.

Image

With the near side wheel arch liner dressed and welded we shall be moving onto the off side next. Upon inspection, this side is a little worse for wear and will require more attention:

Image

Neo Brothers

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Last edited by Neo Brothers on Fri Jul 01, 2011 3:39 pm, edited 1 time in total.

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PostPosted: Fri Jul 01, 2011 3:14 pm 
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UKS Addict
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Joined: Fri Mar 30, 2007 9:14 pm
Posts: 7704
Location: ZZ9 plural Z alpha
Car Model: 2008 93 aero, noob'd
sorry got to ask as i've been on a welding forum.

where are your welding gloves?

and the bloke using cut off wheel where is face shield and gloves?

and long sleeves to protect your arms?

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PostPosted: Fri Jul 01, 2011 3:19 pm 
Oh god, health and safety police around...


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PostPosted: Fri Jul 01, 2011 3:38 pm 
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Saab Nut

Joined: Fri Dec 30, 2005 5:59 pm
Posts: 1641
Location: Lincs
Car Model: 190k 2.2 Tdi minter
melle wrote:
Oh god, health and safety police around...


and those neoprene surgical gloves will melt nicely... :D :D :D

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PostPosted: Fri Jul 01, 2011 3:44 pm 
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UKSaabs Trader
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Joined: Wed Apr 04, 2007 9:14 am
Posts: 2316
Location: Waltham Cross, EN8 7LX
ghost_walker wrote:
sorry got to ask as i've been on a welding forum.

where are your welding gloves?

and the bloke using cut off wheel where is face shield and gloves?

and long sleeves to protect your arms?


Absolutely right, these were the 'posing' shots for the forum. The real work was carried out by a master welder in full protective gear :lol: :lol: :lol:

Neo Brothers

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PostPosted: Fri Jul 01, 2011 3:46 pm 
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Location: Waltham Cross, EN8 7LX
Image

Neo Brothers electrolisis - never wax again :lol: :lol: :lol:

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PostPosted: Fri Jul 01, 2011 3:58 pm 
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Location: ZZ9 plural Z alpha
Car Model: 2008 93 aero, noob'd
just thinking ahead, no point in spending all your time building the new version of the toad if you can't drive the thing due to the burns you got while building it and anyway having a shard of metal in your eye tends to ruin your day!!

might hurt for a few days and require eye drops or you end up blind, but i don't know of any tracks that'll let a blind driver on track, although the roads are another matter :lol:

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PostPosted: Fri Jul 01, 2011 4:22 pm 
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Site Admin
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Joined: Thu Jun 17, 2004 9:43 am
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Location: Aberdeen Stavanger Offshore ou Le Giraudet
Car Model: Most of them!
I have to say that this is a totally bonkers project, and so has the Fat Controllers seal of approval 8) 8)

Nice workmanship, bonkers end project. Perfect!

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PostPosted: Fri Jul 01, 2011 7:11 pm 
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Joined: Fri Mar 30, 2007 9:14 pm
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Location: ZZ9 plural Z alpha
Car Model: 2008 93 aero, noob'd
there you neo's there something to have in the back window

Approved by the Fat Controller!!

certainly be a talking point at the track

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