View Full Version : Stubnose Notchback - Project 8v turbo
Edit!
As we got our own forum now i thought i better edit my project car thread so you all know a little more about the Stubnose Notckback:D .
I've owned stubby for nearly 7 years, she's a C plate 1985/86 2 door 8 valve turbo, due to her being cheap, having a multitude of drivers and well over 200k miles on the clock pretty much everything has had to be replaced over the years, mechanically atleast!
In spring last year (2005) the engine finally started to give up on me and being daft and wanting to keep her on the road i sourced a replacement engine/gearbox which came from a later model 5 door T8, which i collected from a couple of lads in Glasgow (cheers Alan & Craig!), drove back to Birmingham and proceeded to strip apart.
Since i completed the engine swap plans for stubby have grown considerably, which was due in a big way to my own boost in confidence after doing the engine/box swap, armed with my new ability i started to 'tune' her:D .
First mod to go on was the long awaited Twintercooler, which had been over year in the comming and, to accomodate the IC pipework i swapped out the saab headlights for some smaller units which would allow the pipes to run either side of the radiator, reducing their length.
A few months after a fellow Saab Centraller came across some pic's of a Saab 900 FMIC install where they had tilted the radiator to run the pipe work over, which reduced it's length even further, so i then decided to re-plumb in the twintercooler using this approach.
Sucess! The new pipework was a huge improvement, reducing lag drastically, the shorter, more direct route & 2.5" pipework over the previous 2" worked far better, so much so infact that the car started to run badly lean over 2.5k rev's, and was suffocating the engine at full boost:o.
So now armed with a dyno sheet, more mad idea's and a lust for more power i've taken the car of the road for some major tinkering, when stubby rides again she'll have the following:
Twintercooler(cores joined in parrallel) with tilted radiator, minimum IC pipework.
T3/4 hybrid turbo, 3" compressor inlet, 2" outlet, 2.25" turbine exit
3" exhaust sitting on a modified Wastegate housing that has been opened up to allow more flow away from the wastegate.
5th fuel injector using the ColdStartInjector fuel line, solenoid valve & aquamist injector.
Water Injection using a 2nd washer resevoir, 12v caravan water pump, solenoid valve & aquamist injector.
K&Ni mounted on a 3" pipe off the fuel meter head.
Oil catch can
The bodywork is also gradually being restored, the modifications include
17" AEZ luna 6 spoke alloys
Pre-facelift aero front spoiler with enlarged lower lip, aero body kit and a post facelift aero rear bumper.
9000 Carlsson saloon rear spoiler
Sach & Boge sports lowering springs and dampers
Pagid fast road pads all round.
Now back to the thread/car as it developes.
Thought i'd try and keep my stuff in one post now, as it all goes onto the car.
I've been working on removing bits from the engine bay and another little distraction, i took the old rubber rear spoiler off and mounted the 9000 carlsson spoiler to see what it would look like, see what the pitch was like with it mounted directly onto the boot.
Under the rubber spoiler....
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0187.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0187?full=1)
After a quick clean...
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0188.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0188?full=1)
Here's a few with the spoiler mounted...
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0199.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0199?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0198.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0198?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0197.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0197?full=1)
I've got to fix the spoiler down at each end and maybe adjust the line slightly but it should need anymore adjustments (then clean the boot up and respray them both).
At the other end i've removed the throttle body as i've got to do a bit of work on that, a few pic's from the start and end of the day...
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0175.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0175?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0200.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0200?full=1)
I think that spoiler looks wild on there…. Keep up the good work
Tomarse
28-05-06, 11:06 PM
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0200.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0200?full=1)
What is going on here? Looks like your car is supping on a bottle of cider or something!
Rushtrack
28-05-06, 11:53 PM
What is going on here? Looks like your car is supping on a bottle of cider or something!
what, you dont give your car a nice cold one after a hard day's work on her? tissk tissk.....you should buy beers all around
Nice work Si :cheesy:
its looking good will it be ready for Retro Classic's
Paul
__________________________________________________ _
a car with dashing looks to match sparkling performance.......
...
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0175.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0175?full=1)
...
What's that Intercooler?!? two standard 900 intercoolers welded together?!?
nutcase
29-05-06, 08:39 AM
Yup that's Si's patented "twintercooler" :cheesy:
And Twintercooler MkII should be arriving soon:D, it will be ready for Custom & Retro!
This is what i've done with the throttle body, mounted an extra piece on it for the recirc dump valve, 5th injector and WI.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0206.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0206?full=1)
what's it made of, a tin of baked beans? :cheesy:
That spoiler is pretty darn fine-looking - it fits really well. The bridge spoilers for the notchback C900 are quite rare, so it's good you've found a viable alternative. I'll be interested to know what you think of a 25mm boss off the throttle body for the dump valve. Keep the pictures coming ... we all watch with interest.
what's it made of, a tin of baked beans? :cheesy:
Nothing as sophosticated, papier mache :lol: .
It's 76mm aluminium tube with the 25mm T welded into it, the bit sticking out with the holes is for the 2 injectors, both holes are threaded and angled slightly.
The 2 sections fit together with only a small difference in the diameter so i've just jb welded them, i'm also using a bit of jb weld to smooth of the ridge at the entrance to the TB.
Both WI & 5thFI are Aquamist 0.4mm nozzles rated to flow 120cc per min @ 4 bar. They both have Solenoid valves to control flow to the injectors.
I'm using the Cold Start Injector line on the standard k-jet unit and a 12v caravan water pump & washer reseviour for the Water Injection.
APC, Twintercool, Uber downpipe & exhaust and alloys to come:cheesy:
The throttle body is nearly finished and ready to go back onto the car, just got a little more tyding to do, i'll cut the main silicone hose down when i refit the IC.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0209.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0209?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0212.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0212?full=1)
Popped it back on the manifold to see how everything lines up, hopefully when the new IC goes in the outlet will be roughly where the end of the silicone cuff is.:D
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0213.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0213?full=1)
84Saab900TURBO
09-06-06, 05:35 PM
Si, you need a job or something:lol:. You've got waaaaaaaayyyyyy too much time on your hands to do cool stuff to your car:nono;. Looks awesome - I'm jealous:cool:.
Few more bits done, radiators out of the way, new fuel filter in and the resevior for the WI is in place.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0218.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0218?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0219.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0219?full=1)
Tomarse
09-06-06, 08:45 PM
While youve got the stuff out of the way get loads of hammerite on the bottom front x-member before it disapears like all the front members on my C900's have!
Is it only held in place with nuts and bolts? I might just take it off and clean up the whole area.
Tomarse
09-06-06, 08:54 PM
I thought it was welded on.
I'll get some pic's of it on the car tomorrow night, i've been pondering how to put it together for a week or two and finally figured it out:D , at some point i'll probably swap the filter for a 16v turbo one as i bought a 16v n/a one by accident as they don't do 'em for 8 valve's. The position of the filter is sweet though:cheesy:
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0229.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0229?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0227.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0227?full=1)
Is that going through the inner wing then?
It will sit below the headlight, above/to the back of the oil cooler, where the normal IC sits, there's an opening in the front aero kit that's normally hidden by the bumper, if i go bumperless there will be air flow straight to the filter:D.
http://www.saabphotos.com/gallery/albums/Project900T8/K_N_location.jpeg (http://http://www.saabphotos.com/gallery/albums/Project900T8/K_N_location.jpeg)
Received my new clutch and boss kit for the momo steering wheel so hopefully both will be going on the car tonight along with the K&Ni/bottom end of the fuel distributer.
I can't beleive how quick time is going by:o 2 weekends and 3 days a/l to sort the car, just hoping that all i'll be doing on the sat before is vacuuming the car etc and no hardcore rush to get it finished.
This weekend the turbo and manifold are comming off and hopefully the new turbo will go on so i can get on with sorting the exhaust and pre-turbo pipework out, then it's just the CV boots, Pagid pads all round and Back disc's along with trying to sort out the 17's to go on the car.
With any luck the 3 days a/l will be used up sorting some bodywork out to make the car look a bit nicer for the show.
Just sorted out the momo wheel and popped it on, interiors still in bits but it's comming back together gradually:D
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0230.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0230?full=1)
And there's more:cheesy:
Just popped this in, the bottom of the meter plate arm is fouling on the top jubilee clip so it needs some adjustment but it's nearly there:D , definitely the right location for the filter! I'm probably put some fine mesh in front of it to deflect water/dirt comming up off the road.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0235.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0235?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0236.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0236?full=1)
I remembered i have the little air feed pipe kicking about too so though i may aswell use it:D , the entrance will have to go back a bit once the front kit is on but i'll leave it there for now.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0238.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0238?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0237.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0237?full=1)
It's very nearly finished now, just got to clean the last of the excess silicone off i used to seal the st st tube in.
Rather than using 2 cuff's and jubilee clips to hold it in place and seal it (earlier pictures - the meter plate fouled on the tube ) i've now welded a fat edge around the end of the tube, then ground it down so it fitted tightly into the entrance to the meter head, used plastic weld (which bonds plastic & metal) to seal up around the welded edge on either side, finally put a ring of silicone around the top to completely seal it.
It all fits together now, no problems with the meter plate. All that needs doing is a couple of holes drilling so i can cable tie the hole unit to the side using the bits the air box strap clips into.
With the fuel distributer in place:
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0239.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0239?full=1)
Beneath the meter plate:
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0240.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0240?full=1)
Just the bottom end in place:
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0242.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0242?full=1)
Side view of the seal between the pipe and air box:
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0243.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0243?full=1)
The seal from beneath, you can just make out the white plastic weld:
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0245.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0245?full=1)
More progress, new clutch is on:D and the exhaust manifold and turbo is off, hopefully i'll get the new one on tommorow:cheesy: .
New Clutch:
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0246.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0246?full=1)
An empty space!:
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0247.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0247?full=1)
And finally, my 2nd gauge pod:D :
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0248.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0248?full=1)
cinemarr
19-06-06, 03:12 AM
Just sorted out the momo wheel and popped it on, interiors still in bits but it's comming back together gradually:D
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0230.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0230?full=1)
nice wheel. Did you get that boss kit with horn button that I mentioned?
Yep, the boss kit/horn came from moosefarts, luckily, when i emailed them they said they'd sold out, then sent another message saying that they had 4 left, so i got one, then posted on here that they only had 3 left so i think Murray bought one too!Managed put it together upside down, but did'nt realise until i could'nt get the indicator switch off thing to work, and i managed to drop the nut down into the speaker hole and it got stuck so i had to remove the lower knee bolster to retreive it:roll: !
All sorted now, on with the bolt the right way up!
Just a little update, clutch is sorted now (well ish....see the thread!)
I spotted a 2 door T16S on ebay, tempted to get the bridge spoiler but i quite like my 9000 carlsson one, anyway decided to ask after the rear bumper and side section, colour coded white at the moment so they'll be fitted and sprayed along with the boot:D .
More progress:D , exhaust manifold is back on, starting to get the bits for the new turbo lined up, hopefully will be welding them tomorrow.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0277.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0277?full=1)
unkleG'sif
28-06-06, 03:11 PM
More progress:D , exhaust manifold is back on, starting to get the bits for the new turbo lined up, hopefully will be welding them tomorrow.
i'm VERY exited at the sound of that ;)
84Saab900TURBO
28-06-06, 03:37 PM
She's purty Si!!! (the turbo esp.):cheesy:
ejenner
28-06-06, 07:03 PM
Didn't realise you'd started a saab-epic thread. Watching with intrest. Have you been working on the paintwork since I last saw the car at Kodak in 2005? It's looking pretty shiney on the boot in particular!
Didn't realise you'd started a saab-epic thread. Watching with intrest. Have you been working on the paintwork since I last saw the car at Kodak in 2005? It's looking pretty shiney on the boot in particular!
Erm no trick photgraphy i think!. i'm trying to get the boot finished aswell, all the nasty tape stuff that held the spoiler is off, the badges are off and the silicone removed, holes filled, rust sorted just needs a bit more sanding and then wet and drying.
I've ticked another thing off the list, now have cooling!
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0282.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0282?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0281.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0281?full=1)
One last one for the evening, various bits on so as i build the pipe work i know everything lines upand fits OK.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0283.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0283?full=1)
nutcase
28-06-06, 09:53 PM
Looking sweet :)
unkleG'sif
29-06-06, 12:30 PM
where's the fan from si....? looks very thin
would i need one, or is it just for your Mk2?
g
yep, if your tilting the rad you'll need one of those slim line fans, it's 12" kenlowe fan, retail about £100-120 but you can pick them up off ebay for less than 1/2 that.
To get the fan and the rad in i think i'm going to have to cut and move the rad bottom mount a little forward, i'll be doing it this afternoon so you'll see what's needed later on!
Another 8 hrs work......about 5 hrs spent making the pipe to run from the turbo to the fuel meter, with an inlet for the crankcase breather pipe, my recirc and the sol valve, still needs tidying:( but it fits!
Also had to modify the wastegate actuator to fit on the big turbo, it should all fit and work properly now:D .
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0285.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0285?full=1)
Finally sorted the pre turbo pipe!
3" at the turbo end reducing to 2.5" at the meter plate, with a barb for the solenoid valve and inlets for the crank case breather and recirc.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0289.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0289?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0290.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0290?full=1)
i cannot wait to see your car tomorrow Si, are you going to be dragging it!?:cheesy:
I'm not bringing it tomorrow unfortunately, i've still got to finish the exhaust, which i'm missing a bend from to complete so i can't sort that out till next week:( , think i may have upset the neighbours with all the grinding i was doing this morning aswell!
AAAAghhhh gutted! i will take you for a spin in whitey instead! lol its quick as sin for about 2 seconds before the clutch slips lol
nutcase
02-07-06, 04:42 AM
Yeah, was looking forward to seeing your crazy beast of a car again!
Matthew
02-07-06, 12:19 PM
Is it only held in place with nuts and bolts? I might just take it off and clean up the whole area.
The radiator support is held on with nuts and bolts. The crossmember is welded in place, as it's a structural component.
DeLorean
02-07-06, 05:41 PM
when most people say "crossmember" they are talking about the aluminum beam under the car that ties the 2 sections together. the A-arms bolt up on top of it, the skid plate bolts up to the bottom, and you can jack the car up from the center of the cross member, it's bolted in. the section under the rad support that the front motor mount bolts up to is quite an integral part of the car and can not be replaced. I would call that part of the uni-body myself, though I'm not sure what saab calls it. It is quite a structural piece being that it holds the engine in.
Tomarse
02-07-06, 07:48 PM
no, the crossmember people are talking about here is the steel bit right at the front that the engine mount sits on top of... the bit that always seems to go rusty! (has on all my 900's)
If i can remove the radiator support bit at least i can get to the cross member and grind out the rust, weld and repaint. I might end up doing it sooner rather than later as i may have to move the radiator bottom support a little forward aswell.
More progress:D , exhaust manifold is back on, starting to get the bits for the new turbo lined up, hopefully will be welding them tomorrow.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0277.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0277?full=1)
Turbo looks the same as mine!:cool:
http://www.saabforum.nl/albums/Bennie/DSC01608.sized.jpg
http://www.saabforum.nl/albums/Bennie/DSC01610.sized.jpg
Its from Speedpar.s:
Stage 2
TB03/04
Trim 50L
T04E Trim 50L 360˚ axiaallager Stage 2 380pk Max 2,3bar 59.2013
www.speektuning.nl (http://www.speektuning.nl/)
Bennie
spgracer
02-07-06, 10:39 PM
is that a direct bolt up? it doesn't look like it has an internal wastegate.
i am looking for a good turbo upgrade...that one looks mighty nice
I've been test fitting the rear bumper and side panels, they've been glued together and i'm filling the gaps and the bits where the chrome strips go so the bumper/skirts will eventually be one piece, kinda like a mini carlsson rear bumper:D, I'll have to spray it up in a couple of days ones it's all sanded and smooth.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0303.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0303?full=1)
A few more shots, i've put the alloys on with spacers so can't drive it but looks good! Bumper just needs final sanding and respray, along with the rest of the car! I've got to cut the arch covers down a little as the bumper side skirts sit a bit higher than the aero skirts.
I'm going to make a bracket for the front number plate and get one with 2 rows made up, it will bolt in to the bumper mount on the drivers side.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0313.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0313?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0321.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0321?full=1)
A couple more of the front and back.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0325.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0325?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0324.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0324?full=1)
its looking really good si! - loving that rear bumper
Tomarse
12-07-06, 08:47 PM
now get those alloys fitted properly as they look good!
Saabstudent
13-07-06, 01:32 AM
Yeah looking really good Si - maybe one day i'll see it in the flesh?!
Fancy coming along to a WMWSOC meet sometime - well it is local!
G
Yeah looking really good Si - maybe one day i'll see it in the flesh?!
Fancy coming along to a WMWSOC meet sometime - well it is local!
G When's the next meet? Hopefully it will all be working for SOC annual so should be on the road after that, well for a bit as i've got to spend alot of time on the bodywork next!
Saabstudent
13-07-06, 01:57 PM
Si - we usually meet the 1st tues of the month. Not sure of the next one though as its so soon aqfter the national and there is talk of doing a combined meet with the midlands motoring club. Will keep you posted if you like.
G
saabismi
14-07-06, 11:20 AM
I've been test fitting the rear bumper and side panels, they've been glued together and i'm filling the gaps and the bits where the chrome strips go so the bumper/skirts will eventually be one piece, kinda like a mini carlsson rear bumper:D, I'll have to spray it up in a couple of days ones it's all sanded and smooth.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0303.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0303?full=1)
how did you make that?bondo or i dontknow how its written(not wery good at english!:confused:
To join the sections i to the bumper i first mounted the bumper then coated the end sections of the side skirts in plastic weld, pushed them in place and pinned the skirts so they would'nt move/drop, then let it dry and remove the bumper & skirts as one piece.
Once it was off the car i drilled through the plastic tabs on the inside of the bumper & the end section of the skirts, then used self tapping screws to reinforce the join.
To actually fill the bits where the chrome strips were i've used some bumper filler, it's like normal filler but when it sets stays slightly more flexible, to finish off i've used normal filler (mainly as i'd run out of bumper filler)
It just needs smoothing off now and i'll probably use some more plastic weld to finish off as it sets a bit harder and you can get a nicer finish using it.
Took about a day to get to where it is now, i've managed to flatten the joins aswell so once it's sprayed up it will be very hard to tell it's not a once piece bumper.
I think it actually looks a little nicer than the Airflow/Carlsson rear bumper as it's not quite as fat + it only cost £50 inc postage rather than £100 + £70 postage:o someone wanted for a Carlsson rear bumper, i've probably spend another £20 on filler.
unkleG'sif
14-07-06, 12:04 PM
how did you make that?bondo or i dontknow how its written(not wery good at english!:confused:
its from a 9000 Carlsson - our Si is the KING of lateral thinking and crazy ideas;)
http://www.eastsussexsaab.co.uk/images/cars/norse91-9000_02.jpg
its not a good picture I know, but you get the idea
G
saabismi
14-07-06, 12:09 PM
well my son liked it and he plans on building one himself cause i have some of those bumpers in my backyard!
its from a 9000 Carlsson - our Si is the KING of lateral thinking and crazy ideas;)
Only the spoiler is from a 9000, although i was considering getting a 9000 Carlsson rear bumper aswell!
The bumper is a plain old facelift 900s or Aero rear bumper. Glad to see that you can't tell though;) .
unkleG'sif
14-07-06, 12:18 PM
numbnuts here :roll: meant to say "if you mean the spoiler" ;oops:
IronJoe
14-07-06, 03:33 PM
[QUOTE=Si]
I think it actually looks a little nicer than the Airflow/Carlsson rear bumper as it's not quite as fat [QUOTE]
who you callin fat? some people like a lil junk in tha trunk! :cheesy:
http://www.saabcentral.com/phpgallery/albums/album21/PDRM0004.sized.jpg
[QUOTE=Si]
I think it actually looks a little nicer than the Airflow/Carlsson rear bumper as it's not quite as fat [QUOTE]
who you callin fat? some people like a lil junk in tha trunk! :cheesy:
http://www.saabcentral.com/phpgallery/albums/album21/PDRM0004.sized.jpg
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0303.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0303?full=1)
Looking at the two there's actually very little difference between them, so with a bit of extra graft i've saved myself about £100:D
IronJoe
14-07-06, 04:00 PM
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0303.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0303?full=1)
Looking at the two there's actually very little difference between them, so with a bit of extra graft i've saved myself about £100:D
well I bought mine for $25... not sure what that translates to in your funny money :cheesy:
so did you use regular SPG (sorry... AERO) panels or the ones specifically designed for the 2dr/4dr/vert (the ones that came on SiS cars and SE verts)? Looks pro, man.
That spoiler looks great too... I want one for my vert. Still not sure if it'd be overkill or not, seeing as though it already has a spoiler! I may have to pho-sho one up.
It's off a saloon SPG/Aero, there were only 150 sold over here i think, 2 door T16S with colour coded bridge spoiler and aero kit.
Off this car (i also have the spoiler but decided the 9000 Carlsson one was a bit nicer:D )
http://i17.ebayimg.com/05/i/07/84/76/66_1.JPG
http://i10.ebayimg.com/04/i/07/8b/91/50_1.JPG
IronJoe
14-07-06, 06:27 PM
well get to shippin' that spoiler to my house Si!!! :cheesy:
well get to shippin' that spoiler to my house Si!!! :cheesy:
Your too late:lol: , the day i bid on it one of the 99 guys PM'd me and asked if he could have whichever spoiler i did'nt want!
Saab-Daniel
14-07-06, 07:45 PM
Looks nice on the vert we've just bought :cheesy: :
http://img49.imageshack.us/img49/4784/pict02289le.th.jpg (http://img49.imageshack.us/my.php?image=pict02289le.jpg)
Daniel
IronJoe
14-07-06, 08:53 PM
Looks nice on the vert we've just bought :cheesy: :
http://img49.imageshack.us/img49/4784/pict02289le.th.jpg (http://img49.imageshack.us/my.php?image=pict02289le.jpg)
Daniel
:o Nevermind. :o
Saab-Daniel
15-07-06, 12:09 AM
The spoiler on the car isn't Si's old one though... But it really looks nice on a vert too...
Daniel.
Back to the important stuff......tuning!
I've been pondering on the set-up of Twintercooler MkII and i've finally decided that i'm going to give 2 in parrallel a go (rather than MkI which is series)
So my new IC will be have 30 8" long channels(8" width of the core), and will be 19 1/2" deep 2 1/2" wide, it will run across the top front of the radiator with the core passages running from top to bottom.
The distance from the turbo to IC inlet will be around 2" and from IC outlet to Throttle about another 6" longer than it is now.
I'm going to start building it tomorrow and will be re-using the plastic endcaps again, this time there will be no welds, i'm going to rely on JB weld to re-glue the endcaps together and then use some stuff called 'Potting Compound' (used to cover electrical components) as it's cheap (£10 per kilo) and seems to have done the trick sealing up the endcaps on MkI.
The Stubnose Notchback will ride again! Hopefully i'll be doing a hill climb tuition day in Sept to will be interesting how i get on, thinking as the runs are only 20-30secs i should be able to run at about 2 bar boost with WI and not kill the car!
First few stages of the IC build complete, cleaned and stripped, just need to clean the inside now!
The 900 IC's are well put together, most of the performance IC's use the same passage size, and have metal fins inside the tubes.
Mmmmmmm 30 short I passages:D
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0354.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0354?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0355.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0355?full=1)
ejenner
29-07-06, 01:27 PM
Looking good.
Seems like it's all coming together now. Have you sorted out your mixture issues yet?
I have'nt investigated it yet, but i've bought a gas analyser and a WBO2 sensor and dynotune gauge for when i do!
Figured as i was going to be trying to tune the car with a new big turbo and 5th injector i might aswell get a O2 sensor & gauge.
Tom's been using my fuel pressure gauge to sort his fueling out, between us we've managed to come up with all the adaptors needed to connect it and test control pressure and distributer pressure so i'll have a look at mine when he drops it back, plenty to do in the mean time though:cheesy: .
I might be cutting a hole in the front of my bonnet aswell:lol: to give a bit moe flow to the new IC!
A few more trade secrets;)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0356.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0356?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0357.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0357?full=1)
ejenner
30-07-06, 08:30 AM
That looks pretty mean SI. good photo. :cool:
Been doing a little more to the body, i had to cut parts of the front air dam up to fit the first FMIC so i've been repairing it and also done a bit of cosmetic surgery, adding an extra bit to the bottom lip to drop it a bit further, hopefully should help force a little more air up into the radiator/intercooler.
More sanding and filling to be done, but it's starting to clean up quite nicley.
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00010.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00010?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00008.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00008?full=1)
More progress:D , exhaust manifold is back on, starting to get the bits for the new turbo lined up, hopefully will be welding them tomorrow.
http://www.saabphotos.com/gallery/albums/Project900T8/IMG_0277.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/IMG_0277?full=1)
What the size is the rubber bend? Is it 30 degress or 45 degress. And what is inside in mm?
It's (3")75mm bore and a 45 deg bend. It seems to fit nicely around the clutch with another 45 deg pipe
cinemarr
25-08-06, 06:04 AM
Been doing a little more to the body, i had to cut parts of the front air dam up to fit the first FMIC so i've been repairing it and also done a bit of cosmetic surgery, adding an extra bit to the bottom lip to drop it a bit further, hopefully should help force a little more air up into the radiator/intercooler.
More sanding and filling to be done, but it's starting to clean up quite nicley.
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00010.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00010?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00008.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00008?full=1)
That lip looks effn' hot!!! :cheesy:
Eric van Spelde
25-08-06, 07:35 AM
That lip looks effn' hot!!! :cheesy:
Yes, what's it made of and how did you make it? Inquiring minds...
Quote:
Originally Posted by cinemarr
That lip looks effn' hot!!! :cheesy:
Yes, what's it made of and how did you make it? Inquiring minds...
I've added a few more pic's below, the very bottom lip is made from part of the early bumper skin, a while ago i was messing about trying to shorten a bumper and the bottom lip was the left over of the top/back of the bumper skin, very simply screwed into the smaller lip on the air dam then i cut it down(jigsaw) to the right shape, finally about 2 days of filling and sanding to get it smooth and nicely curved. I mostly used bumper fill as it stays more flexible that normal polyester filler, and it sticks a bit better aswell. It's been finished of with polyester filler though cos i ran out of bumper fill.
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00017.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00017?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00018.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00018?full=1)
Oh rust! Been meaning to take my rear light units out for a while to clean them up, and weld up the hole in the boot floor pan, guess i've got a little more rust repairing to do:roll: .
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00020.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00020?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00023.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00023?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00024.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00024?full=1)
I've been doing a little more work on the twintercooler, i'm in the process of making the end cap and inlet for the turbo side, so i've strapped it together and installed with cable ties to start working out how it will line up with the turbo.
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00021.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00021?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00019.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00019?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00017_001.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00017_001?full=1)
unkleG'sif
19-09-06, 02:46 PM
i'd love to live is Si's world... however, i think my head would explode with all the mad ideas he has ;)
way to go dude.... way to go:cool:
G
Well here's a bit more from 'Si Land' :D , just cut the inlet pipe so just the endcaps to go then it can be welded.
So how longs your turbo to intercooler pipe then guy's;) .
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00022.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00022?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00023_001.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00023_001?full=1)
unkleG'sif
20-09-06, 08:30 AM
truly bonkers Si.... love it!
does your bonnet close btw?;)
G
does your bonnet close btw?;)
Yep, just! I could'nt close it completely though as i'd wrapped a cable tie around the bit where the bonnet locks into, but it looked like there was enough space, although i did move it up a little more, should be fine!
Just debating whether to go with the simple solution and use a 2" inlet pipe or try and fit a 2.5" one in, i'm going to cut some tube tonight to see if it will fit, not alot of distance between the turbo and IC so makes building the inlet pipe interesting.
Once it's all in built i'm going to try and put one of the standard rad fans back in, see if it will fit as i've moved the bottom of the radiator forward.
Thought of another install last night, a bit late for this time around, maybe will be MkIII:cheesy: .
I bring you........Twintercooler MkII!
Nearly finished, just need to weld another bit of pipe onto the inlet to get it pointing in the right direction, and i need to strengthen the plastic end a little more.
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00026.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00026?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00025.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00025?full=1)
Gah! Frankenstein :cheesy: I'll be round with a posse to burn your windmill down :lol:
Looking good ... so you went with the parallel version. It'll be interesting to see what you think. For empirical evidence, are you testing with a laser heat probe whatsit, like PDA did?
For empirical evidence, are you testing with a laser heat probe whatsit, like PDA did?
Nothing so sophisticated i'm afraid:D , i won't really be able to compare to before as quite a few things have changed, but in theory i could swap back to MkI to see if there is any real difference.
I may end up making MKIII as i'm not too sure the plastic end is going to hold up, i've got a feeling the cap will split under pressure.
Albert Trout
02-10-06, 09:30 AM
I've said it before Si. You're a maniac. Looks great mate :cheesy:
I've said it before Si. You're a maniac. Looks great mate :cheesy:
Well, never wanting to dissapoint:D , i may have to crack the plastic end back off at some point and weld another aluminium one on, the epoxy cracked under the heat from the welding, i've dumped a load more on but it may split under pressure, especially as i'll be running 1.5 - 2 bar with the new turbo:cheesy: .
As usual by the time i'd nearly finished it my welds were getting alot tidyer, kinda why they are so fat, had to cover up all mess underneath!
Will hopefully get it cleaned up this week and the metal tabs welded on to hold it in place and some to mount the radiator to, then can finaly get it fitted to the car at the weekend, wo hoo, may even get her started!
Tomarse
02-10-06, 05:09 PM
all looking cool! :)
you will have to get an ally end cap made up to replace the plastic one.
I've still got your fuel pressure testing stuff. Will try to get them back down to you at the weekend if i have time and my GL passes its MOT! (cant really afford to do the drive on petrol in the Turbo :( ) I need to measure up your old 2.5 downpipe too!..
A little bit more done on the install, still not quite sure how i'm going to connect the turbo to the IC as the gap is quite small so there's limited space to get expanding cuff in (2" @ turbo 2.5" @ IC).
I also had one arm of the fan mount bolted to the turbo, i've taken that off and made up a bit so that it can be bolted to the radiator/IC, which should keep the fan a little more steady.
Welded a few tabs on the IC so it sits in place, i need to add a few more places to bolt it down to stop it vibrating/moving about or banging the radiator, once i've got all the tubing in place i'll add a few more bolting points.
And the bonnet definitely closes with the IC mounted there!
Also need to relocate the coil & solenoid valve, they will probably end up being mounted on the IC, so will have to weld a couple more tabs on.
Pic's so far.....
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00033.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00033?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00032.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00032?full=1)
ejenner
22-10-06, 04:46 PM
Looking good Si. I take it you're sticking with the tilted radiator then? Will you be able to use the standard top hose to the radiator or will you have to use something else?
Yep, sticking with the tilted rad, i've overcome the last hurdle and got the fan on, i am however a bit stumped as to how to get a connection from the turbo to the IC, it's a bit easier when you've got about 2ft of pipework to plumb in (like on all the other installs), having a 2" gap makes things a little more tricky!
I used a cut down radiator top pipe and a flexi pipe on the origional install, i think it should still work OK.
http://www.saabphotos.com/gallery/albums/Project900T8/DSC01567.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/DSC01567?full=1)
ejenner
22-10-06, 06:00 PM
How about one of these? .....and maybe a couple more angles...
http://www.samcosport.com/images/large/sr.jpg
I've got a few bends and a 2-2.5" cuff but the angles need to be quite sharpe and the bends ar'nt quite tight enough.
I'll probably cut the IC inlet right back and use a reducing cuff off that, then some steel tube to make a mad tight bend to connect them.
A little job for next weekend, hopefully i'll be able to get on with the exhaust once it's sorted and then actually get the car started!
MkI & MkII install were childs play compared to this one, it's taken every last bit of my inginuity to sort this out!
Getting there though, everything is mounted, the diy cuff fits, just needs the inside bore on the turbo side reducing, and cut/reweld the IC to TB pipe, which i'll hopefully get onto later.
Here it is so far:
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00041.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00041?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00039.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00039?full=1)
Well i'd managed to source another 900 intercooler and a second one will be on it's way to me shortly, i have also ordered some more 2mm thick aluminium sheet for the new endcaps, i'll be building MkIII alot sooner than anticipated:D .
It will be very similar to MkII, but with both endcaps made of aluminium, and i will move the inlet over so that it sits directly above the turbo compressor outlet.
MkIII should be a bit tidier than II and should hold the pressure without worrying about splitting the end caps, they will both be solid!
I've been considering welding some baffles into the IC to distribute the airflow from the turbo a bit better, but all depends on how complicated it will be to get them in place.
I'll probably carry on with general bits and bobs this weekend and build MkIII next w/e, so slowly getting closer to getting the beast back on the road, just hope there are no issues with the tilted radiator when i take it for an MOT.
I'll be moving onto my tolulene injection system soon aswell:evil: .
;oops: I've got one intercooler core with 15 small channels and another with 10 wide ones, so the hunt continues!
In the mean time i've got hold of a brand new but cheap radiator which i'm going to try and cut down and weld endcaps onto, i'll drop the height by about 2 3/4 inches so that there's enough room to run the intercooler pipes over the top, both the radiator and the intercooler will be mounted horizontaly whilst keeping the FMIC pipework as short as possible.
I've also decided to loose the internal wastegate and actuator and go with an external wastegate, i've got a metal flange to fit the dump pipe & wastegate pipe to the exhaust side of the T3/4:D, just need to find someone to machine out the hole for the wastegate pipe.
Progress is slow but i'm getting there!
ejenner
14-11-06, 08:01 PM
Progress is slow but i'm getting there!
I'm finding this is a problem with my project as well. I start working on something but I find something else that isn't good enough and I get side-tracked. What I've decided to do is set myself a spec I'd be happy with so I've got something to work towards.
I've been chipping and changing a bit too:D , maybe we are destined to have a kind of 'eutopian' Saab, which ofcourse will never exist:cheesy: .
I think i've got a reletively set plan now, only problem is as soon as i finish this round, i'll have to change some of it again, then again...... I suppose replacing the ignition and FI are quite big steps on an 8v though.
I never would have considered building a radiator either, just getting better at alloy welding so i kind of thought 'why not'!
Graham Bell has also got alot to answer for, should have never bought those two books:lol:
Ugggghhhh Homer style:D i think i've got far too much of a fascination with shinney metal things!
Also decided to build Twintercooler MkIII out of 2 all alloy intercoolers, so as i've got one already i decided to bid on an ebay one, someone outbid me by 1p:evil: .
So i think i'm on about plan K now, which is to cut the caps off the all alloy one i have and weld it to the other spare core that had 15 channels & plastic endcaps.
Anyway back to the engineering porn!
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00052.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00052?full=1)
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00053.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00053?full=1)
ejenner
15-11-06, 07:30 PM
The question didn't really apply back in June 2005 as to weather it was better to buy an off-the-shelf intercooler or to go for a homemade item. Now however, after spending god-knows how much on bits and pieces including welding consumables, chemicals, spare parts, materials, ect, ect.... why are you still trying to make an intercooler? :lol:
The question didn't really apply back in June 2005 as to weather it was better to buy an off-the-shelf intercooler or to go for a homemade item. Now however, after spending god-knows how much on bits and pieces including welding consumables, chemicals, spare parts, materials, ect, ect.... why are you still trying to make an intercooler? :lol:
Every time i make one it I get a better at all the pre-fabbing stuff, I don't want to run with MkII as i don't think the plastic endcap will hold up, and at £50-60 on intercooler's (6 so far, but only bought 3, 1 of which i will sell on at some point cos it's the wrong sort) max i still have'nt spent as much as an off the shelf one.
Final reason, no one makes one to fit where i'm putting it, MkIII's inlet will be even closer than MkII as i'm going to put it straight above the turbo compressor outlet, so i'll only have one pipe 24 inches long max, and total bends will be 180 + 90 + 90 + 90 = 450 degrees, dunno about the pipe work that runs under the headlights to the FMIC's but the standard IC set up has 90 + 90 + 180 + 90 + 90 +90 = 540 degree's of angles in the air flow from turbo to throttle.
If you look at my track record with exhausts it's similar:D , made the 2.5" downpipe, then spend ages modding a wastegate housing to take a big dump pipe, now i'm going to make the exhaust with a separate pipe for turbine and wastegate:roll: .
IronJoe
15-11-06, 08:08 PM
max i still have'nt spent as much as an off the shelf one.
Like the old aircooled beetle saying, it's only cheaper if your time is worth nothing :o But I commend your efforts nontheless, as I've been guilty of spending WAY too much time and effort in the past!
Boy, with all these new mods you might actually be able to keep up with a stock T16!! ;)
Boy, with all these new mods you might actually be able to keep up with a stock T16!! ;)
By the time i'm finished i'll be up there with some descently tuned T16's! Once i've swapped to EFI & digi ignition control, the cylinder head has been ported/polished, fast road cam and enlarged inlet valves added i hope to be getting close to 240-250bhp:D .
Received my new radiator today, have to say the Audi/VW/Skoda/Seat radiators are nice pieces of kit, the core is 440mm wide & 320mm high, looks quite a it shorter than the standard 900 radiator so hopefully i won't even need to cut the top passages and reweld on the endcaps, i might be able to use it, as is:) .
If it goes in OK i'm probably going to buy 2 small radiator fans, rather than the single slim line one, hopefully that should solve any cooling problems caused by running with a smaller radiator.
Just my EDIS stuff to come now (Albert!!!!!) and the exhaust flanges from the US, once i've got them i'll order some 1 1/2 inch tube to weld up the external wastegate pipes.
Albert Trout
16-11-06, 11:52 AM
Procrastination is the thief of time ;oops:
Do you have an intercooler you can stick on the car, just so you can drive it round a bit? If you don't stop making intercoolers, you'll never get around to EFI, mapped ignition and all the rest. I went absolutely mental when my car was off the road. Currently, its not in perfect running order, but I don't care, I'm driving it.
Procrastination is the thief of time ;oops: Erm yes, i think half my problems are caused by pondering whether something will work then spending god knows how long trying to make it work!
So just checked and the height difference between the 2 radiators is 50mm, Saab one is 370mm, my new one is 320mm, ideally i need about 70mm clearance to run the pipes over the top, so i think i'll probably cut the lower rad support off and try and gain the 2cm at the bottom, rather than a cut/shut job on the radiator it'self.
Should have some pictures as it comes together over the weekend.
I'm running about in an 8v injection at the moment, i can't afford to have both cars tax'd and insured so i'm working towards a swap in mid december when injection runs out of MOT.
Drg has just had MkI off me so only got the 3 standard IC's and MkII at the moment.
I've also got a bit of welding to do before i can MOT it so not a huge issue chopping and changing, just a bit of a PITA.
Still atleast if i do this it will be there for other people to not make the same mistakes! And the end result should be more than worth it:D
Here's the radiator, looks like it's alot more efficient than the standard radiator, the water channels run through a very tight matrix of cooling fins, rather than the usual channel/fins arrangement, the channels are alot wider than the normal radiator aswell.
Ideally i think you need a radiator catalogue to go through and match up the size as closley as possible, but as this one was £10 it will give me something to mess about with for the next few months, if the car starts to run hot towards the summer i'll probably spend some time matching a radiator up exactly.
Oh and PM's now cleared!
http://www.saabphotos.com/gallery/albums/Project900T8/PIC00054.sized.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00054?full=1)
unkleG'sif
17-11-06, 08:27 AM
what model VAG rad is that exactly Si?... none of my enquiries have been fruitful
G
It'a a bit too small i think Drg, sat and thought about it last night, it's gonna be too much hassle to make all the extra baffles to stop air flowing around it, so i'm either going to keep it and make a couple of chargecooler radiators out of it or sell it on.
I've got to go and find a specialist radiator place and see if i can either find an off the shelf one exactly the right size, or get a core made up.
unkleG'sif
17-11-06, 09:54 AM
gutted - custom rad is gonna be well pricey
I don't think it will be that much more than a standard radiator to be honest, Tomarse has had a couple recored and bought one for his Ambulance which was'nt custom, but was size matched from a catalog, i don't think he payed much more than £100 for the rad he got.
If i manage to find one from another make that fits i'll post the details as there's actually a few of us who think this is a worthwhile approach;) .
I got the stainless steel flanges to make up my exhaust with the external wastegate today:D , just got to find someone to bore a hole in it for the wastegate exit now.
OK, so i have a dilema.......:confused:
Probably going to go to this place tomorrow if i get time,
http://www.serckintertruck.co.uk/
I'm going to either buy an off the shelf radiator that is the right size or if it is not to much get a custom one built.
But i'm getting tempted to get them to build an intercooler for me aswell, and that's the dilema! If i do i'll probably get the intercooler built so it has the same sized core as the radiator (thicker though obv.) with the inlet & outlet similar to MkII.
I guess it will come down to the price, i think i'll probably go upto about £250 for the intercooler, i don't think i could justify spending any more since the ebay ones are only £150 at most.
I guess the real question should be is it worth spending £3-400 to get the perfect intercooling set-up?
Tomarse
17-11-06, 06:38 PM
I got the stainless steel flanges to make up my exhaust with the external wastegate today:D , just got to find someone to bore a hole in it for the wastegate exit now.
where did you get the flange from?
The radiator place i recommended near me also do IC's. They have alwasy had loads of monsterous truck ones leaning up when i've been there!
A guy I know has had bad experiences with serck (or atleast the branch near him) when they sold him a refurbed radiator which was just and old one that had been resprayed so i've always used the local place instead.
I got the flange off ebay, shipped from the US, very good though, bought it on mon/tues and got it today, that's quicker than alot of stuff i've had from the UK, they also labled it as 'free trial diesel test parts':cheesy: so no extra duty!
Do a search for T3 flange, there's only one place that does them.
The External wastegate was missing one of the flanges, but i got the flange for that, the WG flange, cat flange and the exhaust manifold-turbo flange in the kit.
I assumed that a referbished radiator would be chemicaly flushed, then kind of electro plated to thicken the metal and seal any pin hole leaks, spraying one does sound a bit iffy!
Did'nt have time to go to the radiator place, but i've got all the dimensions down properly, i'll probably email a few companies to get some quotes.
[/url]
http://www.saabphotos.com/gallery/albums/album474/radiator.thumb.jpg (http://www.saabphotos.com/gallery/Project900T8/radiator?full=1)http://www.saabphotos.com/gallery/albums/album474/intercooler.thumb.jpg (http://www.saabphotos.com/gallery/album474/intercooler)
[url="http://www.saabphotos.com/gallery/Project900T8/intercooler?full=1"]
There is an interesting articly in the November 06 (issue 31) practical performance car about aluminium radiators and intercoolers this month! Alisport go through making a custom one. the welding on that radiator will make you wet!:o
Cool, cheers Murray, i will ava look for it in the local newsagent.
nutcase
30-11-06, 09:22 PM
the welding on that radiator will make you wet!:o
Why, is it that bad? ;)
Why, is it that bad? ;)
Squirting everywhere when i looked at it! real messy! :roll:
Bit more bodging:D, as i've got a pipe comming straight off, i had to come up with another way of securing the meter plate & fuel distributer, this should do the trick.
[/url]
http://www.saabphotos.com/gallery/albums/album473/PIC00065.thumb.jpg (http://www.saabphotos.com/gallery/Project900T8/PIC00064?full=1)
http://www.saabphotos.com/gallery/albums/album473/PIC00064.thumb.jpg (http://www.saabphotos.com/gallery/album473/PIC00064)
[url="http://www.saabphotos.com/gallery/Project900T8/PIC00065?full=1"]
Finished the mount for the metering unit, and started scraping away the sealer on the boot floor so i can cut away the rusty bits (i'm up to 6 holes in the bodywork now!) The POR15 stripper does the trick, i've been spraying and scrapping off the sealer, and i'm down to metal on most of the aera that needs cutting and welding.
http://www.saabphotos.com/gallery/albums/album473/PIC00070.sized.jpg (http://www.saabphotos.com/gallery/album473/PIC00070?full=1)
Saab-Daniel
17-12-06, 07:39 PM
Si, what is the name for the Por15 rust-stripper you've got? I've just bought a set with metal-ready, marine-clean and Por15 paint, and need to know if I need anything else?
Daniel.
ejenner
17-12-06, 07:53 PM
What's that little canister you've popped in the corner there? Can't really see what it is.
Daniel, it's called POR-strip, it will take paint off the body with one spraying, a couple on undersealer, and a sh1t load to get through the thicklayer in the spare wheel compartment bit, but does the business:D .
Emmett that's the oil catch can, i've got to weld a nipple onto the meter head-turbo pipe to finish connecting it up.
That's an interesting location for the catch can ... well thought through :cool:
Well as some of you may have seen, i've now got a new daily driver, so stubby is in for a full restoration, over the next few months I will be:
Removing all the interior including headlining, removing the fuel tank.
Treating all body rust, welding up any holes.
POR-15 all bare metal in the interior and all the seams in the underside along with any area's that have been welded.
I'm going to take the doors off the 8v injection, they will be treated and welded then once they are resprayed they will go onto stubby, with the manual window winders, they will also be delocked and actuators added for IR central locking.
Removing all the gubins for the electric sunroof, to be replaced with a manual sunroof.
Cut an access hole for the crank pulley so that the EDIS trigger & sensor can be mounted and set up with the engine insitu, make a cover to bolt over the hole.
Complete respray of the exterior, all dits/bumps blemishes will be filled and sanded, de-badged.
In the mean time i need to finish the intercooler and the exhaust with separate exit for Ext wastegate, once that is done she'll be ready to fire up, once the bodywork is completed she'll be back on the road:evil:.
ejenner
14-01-07, 06:47 PM
Don't get too carried away Si. I made that mistake and I've still got a long way to go. I do want it to be good but I'm finding good ways to compromise because I want to get it finished. i.e. I had wanted professionally fitted carpet but for the time and money required I'm going to put that item on the back-burner. I've bought some eBay carpet from 'Kit' on UKSaabs and I'll stick that in for a year or two.
The main thing is to remove all the rust and get it all POR-15'd so i never have to do it again! It may take 6 months to sort the body out, but then hopefully it will be good for another 21 years!
I've found that there is various bits in the interior that are starting to rust, i guess from condensation build up, so carpets got to come out really.
I've also had/got very bad rot around the rear wheel arches, so i think i need to get to the drainiage tubes from the sunroof and replace them.
Will get there eventually, i'm not going to offer to race you to completion as yours is going to be so much tidier than mine!
I'm back:cheesy:
Finally decided what to do with Stubby, she's being turned into a bespoke track car, i'm in the process of stripping her back to a shell, apart from the engine and suspension, i'll sort out all the rust then figure out exactly what goes back in.
I have'nt decided whether to run with an aero kit yet or just the stock pre-facelift front air dam and the back bumper i put together, it's extra weight, the main thing i am going to concerntrate on is weight reduction and increasing grip as much as possible, so will be running semi slicks.
I'm still going to upgrade to EDIS, EFI with megasquirt controlling things, and run the huge T3/4 turbo, with either a intercooler & stock inlet manifold or a charge cooler integrated into the plenum & twin throttle bodies.
Anyway a few pic's of the strip down.
http://www.saabphotos.com/gallery/albums/track-car/PIC00119.sized.jpg (http://www.saabphotos.com/gallery/track-car/PIC00119?full=1)
http://www.saabphotos.com/gallery/albums/track-car/PIC00120.sized.jpg (http://www.saabphotos.com/gallery/track-car/PIC00120?full=1)
Welcome back, mate ;)
I think you're making a good decision. TBH, it was getting less and less like a road car with every post you made (before buying the Vauxhall) and thus less likely to be a reliable road car. Enjoy the "Vectra" for day-to-day and have your proper fun in the old heap.
I reckon your should keep the body kit ... okay, it's weight, but you're not exactly fat, are you? You should lose the front bumper (and rear)to compensate - flat nosers look evil with the front air dam exposed :cool: You can use those light T-shaped bumpers, like on old Beetles. What wheels will you run? Those 17s, or do you want some proper 15s at 7" wide?
I'll put the semi slicks on the 17's for track/show use, and just run some 15's with any old rubber for getting about.
I'm just trying to decide whether to completely respray the car black or stick with metalic grey, i'll be doing all the bodywork and rust repairs to last so will give her a nice coat of paint aswell. I need to make a decision about the aero kit as if i don't put it back on i'll have to fill the holes that the rails fit to.
The classics are probably more suited to track use, the NG was good fun but i don't want to sacrifice the ride quality to get better handling, it really needs it if you want to take corners at speed:D.
ejenner
24-04-07, 09:25 PM
This is a good style!
http://www.saabtuning.de/fotos/saab4.jpg
...and I'd probably go for something lighter than black. Black track cars never look like the best ones when you watch a whole bunch of track-cars flying past. Equally, I'd not go for anything too garish either. Difficult. If you could maybe combine the silver with a dark-green lower half, that'd look pretty slick I reckon! Dark green lower vallance, dark green wings, dark green kit and lower part of door's, dark green boot lid and rear wings and c-pillars. Silver roof, bonnet, upper doors and under the rear windows.
Agreed! The dark metallic is a good base coat, but detail with a complimentary lighter colour with Psytuned down the sides, or on the boot, and Si-cho (or Si-cko :cheesy: ) at a jaunty angle on the bonnet.
I like yellow, but I'm thinking a light beige would be a lighter opposite of the metallic grey :o
Wheeeeeee!
http://www.pjgh.pwp.blueyonder.co.uk/saab/specials/images/Rally%20900%20002.jpg
I always thought ruby red would go nicley with metalic grey, but would probably be a bit too bling, need another colour to tone it down a bit, maybe silver on the raised bit of the hood, the roof and the boot lid, then met grey and a ruby body kit:confused: .If i get it running for Croft i think it'll still have CIS and a dizzy, MS will have to wait a few months.
Tomarse
25-04-07, 11:47 AM
finally came to your senses! :)
you should stick with the aero kit in the style of the picture EJ posted as that looks pretty sweet.
unkleG'sif
25-04-07, 11:47 AM
I reckon! Dark green lower vallance, dark green wings, dark green kit and lower part of door's, dark green boot lid and rear wings and c-pillars. Silver roof, bonnet, upper doors and under the rear windows.
Scarabe Green is pretty nice - and would go really well with silver or grey :cool:
http://www.saabphotos.com/gallery/albums/drg23/Saabarella_Side.sized.jpg (http://www.saabphotos.com/gallery/drg23/Saabarella_Side?full=1)
G
What's the paint code for scarabe green & gun metal silver?
The aero kit should be 2 tone i think as it's got a nice line down it to separate the colours, maybe the wings & doors should match the lower kit and have another colour on the upper kit, bonnet, roof & boot lid.
unkleG'sif
25-04-07, 02:14 PM
Si
i have no idea what the code for silver would be.... i guess there are many, and you could choose your fave.. but i know that Scarabe Green's code is 230 :cool:
G
have a look thru here (http://www.saabworkshop.com/index.php?page=workshop&article_id=5)
TheRedBaron
25-04-07, 02:25 PM
That saabhistory site has a list of paint codes, with probably inaccurate color swabs.
I reckon you get the bloody thing going first, and then start worrying about the paint. Priorities!
TheRedBaron
25-04-07, 03:28 PM
I reckon you get the bloody thing going first, and then start worrying about the paint. Priorities!It's easier to paint with all the stuff removed, though, you have to take it off anyway to do the job right...
Naa, i'll just push it round the track:cheesy: .
OK so what about Cherry Red(127)/Silver(172) with Odoardo Grey(158):D
I think the silver and green is a really good idea. But eh, get it running!
What do you need to do to achieve that?
Fit intercooler and all hoses
refit CIS
fit all turbo lines and hoses
turn key
Come on!
Little bit more than that i'm afraid, got to drop the fuel tank first so i can weld up the bloody gapping great holes!
To get it done quick i may even plumb in a stock intercooler:o
Main things outstanding that will take time are
Finish building exhaust with external wastegate
Replace inner & outer CV boots
Replace rear brake discs and pads all round
Machine hub spigbots to fit 17's
Lots & lots of patching/rust removal
Refit front seats & seatbelts, knee bolster
Renovate doors and replace the ones on the car
Swap sun roof for manaul one
probably a fair bit more aswell, will be removing the headlining tonight i think.
Good news is i've got very little to do on the NG, just replace the gear lever movement sensor, which will take about 30 mins at most.
Bawheid
25-04-07, 03:54 PM
How about a Starsky and Hutch red and white?
http://www.saabphotos.com/gallery/albums/album479/red.jpg
Or a bright orange with a dark grey or really really dark blue aero kit. No point not being seen :D.
Hmm, well at least I've prompted the creation of a checklist :)
Are you sure you want to ruin those nice 17's with brake dust? :)
I think you should probably weld in braces where the sunroof goes, stiffen the shell a little bit.
Little bit more done, headlining is out, most of the interior stripped now apart from the rear parcel shelf and the top rear seat belt mounts.
The colour options is quite prudent to think about, i'm going to be working on the body solidly until it can be resprayed and it is all sound enough to get through an MOT, then i'll move onto getting it running and sorting out the mechanical bits so it passes the inspection, once it's MOT'd i can work on sorting out the engine management.
Oh i'm thinking about getting the 17's powder coated black, so brake dust won't be a problem:D , i think they are a bit lighter than the 15's aswell.
Finished stripping it out, just the sunroof assembly to remove, did'nt do much on the car over the w/e apart from a little tinkering, i'd cut bits off the front air dam for the first intercooler install, i'd bodge repaired it but the bar which sits under the grill kept on braking off, so decided to cut up the stock air dam from the 8v injection. It can reletively easily be jig-saw'd to shape, it's all finished now, just siliconing an air duct onto the passenger side vent so it feed air direct to the cone filter.
All the front air dams, stock one with the side sections already cut off
http://www.saabphotos.com/gallery/albums/track-car/PIC00155.sized.jpg (http://www.saabphotos.com/gallery/track-car/PIC00155?full=1)
Now you have to jigsaw the vent holes
http://www.saabphotos.com/gallery/albums/track-car/PIC00157.sized.jpg (http://www.saabphotos.com/gallery/track-car/PIC00157?full=1)
And refit the vents
http://www.saabphotos.com/gallery/albums/track-car/PIC00158.sized.jpg (http://www.saabphotos.com/gallery/track-car/PIC00158?full=1)
Finally ready to be cleaned up, screwed back together and sprayed.
http://www.saabphotos.com/gallery/albums/track-car/PIC00159.sized.jpg (http://www.saabphotos.com/gallery/track-car/PIC00159?full=1)
Got around to removing the sunroof assembly, i was quite suprised how heavy it was, i was just going make some brackets to pin the sunroof lid back in place, but may end up going with a sheet of plastic instead to reduce the weight.
http://www.saabphotos.com/gallery/albums/track-car/PIC00168.sized.jpg (http://www.saabphotos.com/gallery/track-car/PIC00168?full=1)
http://www.saabphotos.com/gallery/albums/track-car/PIC00164.sized.jpg (http://www.saabphotos.com/gallery/track-car/PIC00164?full=1)
http://www.saabphotos.com/gallery/albums/track-car/PIC00162.sized.jpg (http://www.saabphotos.com/gallery/track-car/PIC00162?full=1)
ejenner
07-05-07, 08:19 PM
Wonder do you get any extra strength for having a steel pannel welded in?
There is already a frame welded in around the surround so i don't think it would make that much difference.
I'm contemplating removing the heater matrix and using the main vent on the bonnet to cool the engine bay so i could have a roof scoop on one sunroof and a normal second one, then swap the vented one in when needed.
ShadowWorks
07-05-07, 09:37 PM
Could you take the top metal skin of the sun roof and weld it to the top hole?
How does the panel that moves backward and forward come out?
I need to retrim the fabric on my sunroof and I'm chicken to take it out:lol:
Sun roof comes apart dead easily, just open it half way and remove the two screws, then you can start to disassemble it.
The lid it just a sheet of metal with a small frame around it, but both are slightly to small, you need the rubber sill to make it fit tight, i'm thinking of making it with a couple of quick release catches on, so it's kinda like an emergency exit:D
ejenner
08-05-07, 07:42 AM
Here's how BIRDIEMANGO did it.
http://www.red-green.co.uk/web/photos/saabpics/birdie_sr_removal_001.jpg
http://www.red-green.co.uk/web/photos/saabpics/birdie_sr_removal_003.jpg
http://www.red-green.co.uk/web/photos/saabpics/birdie_sr_removal_002.jpg
faster4_tec
08-05-07, 11:44 AM
other than to save weight, why would you want to remove the sunroof??? I crave a sunroof in my next car, its almost top of priorities:D
Primarily to remove weight which sit's quite high up so should also drop the CoG slightly, i think the roof and assembly must weigh about 20kg's.
I think BIRDIMANGO must have done away with it completely to help stiffen the shell a bit, and with just the roof skin in place it probably leaks slightly aswell.
The car will be a pure track thoroughbread so no need for mod cons like an interior, heating, electric windows and sunroof!
Tomarse
02-06-07, 10:27 AM
Primarily to remove weight which sit's quite high up so should also drop the CoG slightly, i think the roof and assembly must weigh about 20kg's.
why dont you just buy a univeral sunroof and fit that in the old hole. They are only really a sheet of glassy/plastic stuff with some hinges! - probably no different in weight to the metal you could fit instead and would offer some nice cooling.
really considering fitting a sunroof on my gl at the moment now it is sunny and nice out!
I'm going to use those lotus 7 style bonnet catches i think, doubles up as an emergency escape hatch!