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: Renovation-of-900-CV-1991


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misu
25-12-06, 10:50 AM
Hi all,

even I am a novice here, let me show You my own, similar project.
http://saab-900cv.rajce.idnes.cz
It is 91' 900T16 CV in very bad state, I mean long time careless car, what moved last time around 8 years ago (check sticker on windscreen)...
As You can see, I am at begining, but I still run forward...

dtsirlis
25-12-06, 11:20 AM
Wow man, looks like allot of work. Cant wait to see what you do next!

misu
25-12-06, 11:59 AM
Well, there is a lot of work on removed components. Untill today I have repaired and ready to be mounted back the whole dashboard (except wood inserts, what are a long term run - glue veneer, sanding, first cover of epoxy, sanding, painting to the red and a couple of clear acryl), gear lever, center console, headlights, front light clusters, rear light clusters, lock mechanisms for doors (trunk mechanism is still on the car), all lock barrels, rear window lifts, interior door covers, rear side covers, front safety belts, front mask and that all, I think...

Today evening I want to repair front window lift, I think just one only, second will do tomorow. Also wipers are waiting, rear belts...
I have to repair and make some modifications on the main wire loom, fit alarm, and prepare system for DI, or, as my good friend advise, for Trionic. Because he has Saab service, Tech 2, all necessary components and knowledge, how to modify it, there is a good chance we win... :cool:

misu
25-12-06, 12:41 PM
I'm a little confused here. you state its a '91, but it is a flat front - AFAIK only made on the convertible in '86 for export to the USA, facelift cars were made from the '87 model year, for sale in europe as well.
It also appears to have an 8V engine, not a 16V. - what's the story with the spec.?
Good luck with the rebuild.
Dan.

Previous owner (son of my friend - Saab service owner) tried to modify '91 into pre '86... Thats reason, why there were flat headlights and 8V engine. So I decide to return all things back, as it should be, except computer system.
Well, see You tomorow, I am going into my "cave"...

misu
26-12-06, 07:11 AM
Well, I did what I want to do... One front window lift. This one was the worst. I've spent two cans of brake cleaner spray for it. But now works as a new one.

So today I will do the last one and, because it looks much better, I will try to do wipers too.
One interesting thing concerning alarm. When a car is among the others at the parking, usually in dark, it is very easy to steal it. So I want some equipment, what should work on this way: You have to press any hidden button briefly and then you have around ten seconds to start. If You do not press that button prior to starting, engine (ignition) will stop the engine after approx. three minutes, when the car is at some larger street, near some crossing, etc. and will not be able to start for next three minutes. This "black box" will be complete independent, without any connection to alarm, without any connection to GSM, or another devices.
What do You think about that?

nbell
26-12-06, 10:32 AM
So I want some equipment, what should work on this way: You have to press any hidden button briefly and then you have around ten seconds to start. If You do not press that button prior to starting, engine (ignition) will stop the engine after approx. three minutes, when the car is at some larger street, near some crossing, etc. and will not be able to start for next three minutes. This "black box" will be complete independent, without any connection to alarm, without any connection to GSM, or another devices. What do You think about that?

Why not just get a regular immobilizer? You don't have to have a noisy alarm, an immobilizer stops the car being started. These are easy to hide somewhere and cheap. You can have the deactivate button on your key ring.

Your idea is ok but...why let the thief drive it anywhere at all? You won't know where to find it - and they may crash it if the engine cuts out on a fast road.

misu
26-12-06, 11:20 AM
Why not just get a regular immobilizer? You don't have to have a noisy alarm, an immobilizer stops the car being started. These are easy to hide somewhere and cheap. You can have the deactivate button on your key ring.

Your idea is ok but...why let the thief drive it anywhere at all? You won't know where to find it - and they may crash it if the engine cuts out on a fast road.

I have immobilizer on my alarm, but thief can disable it - when some alarm is produced in a huge series, there is something what can "break" it on the market...
When You let them to drive the car for just two or three minutes, they will not be so far from you. But the car will be in the middle of some main street, bad place for thief to try disable this type of immobilizer, worse then a quiet, dark street or parking bellow trees...
My equipment would turn hazard warning flasher too, so everybody, even a police, will see, that is something wrong.

misu
27-12-06, 05:20 PM
And I did...

Last window lift, wipers mechanism and glove box wood veneer. Tomorow I will sand and aply first layer of epoxy on it and maybe I will clean all sealing strips for windows.

I have a big dilema now - what colour? Originally car was black with black interior, but it looks like a cofin... I can change external color, my favorite is Talladega Red, or change color of interior - beige. I have to carefully check original paint, maybe it will not be necessary to paint a whole car, just bonnet, left front wing and left doors... In this case it will be better (and cheaper) to change interior colour...

cdaly
28-12-06, 04:45 AM
Because you have stripped out the interior, and you will have to do some rust-proofing work there, you will need to do some painting on the interior. In that case, if you can afford it, you could consider changing the car's colour. If you had not stripped the car, changing the colour would be harder because you would miss something and it would show later.

scubasaab
28-12-06, 09:08 AM
A quick note on the woodwork.
Epoxy is not the stuff for woodwork.
It is not UV stable and will yellow and eventually peel.
Man O War marine spar varnish or eurethane. Varnish is really nice, but it takes a VERY long time to cure fully and stinks for a while!

First SAAB
28-12-06, 05:27 PM
I have a big dilema now - what colour? Originally car was black with black interior, but it looks like a cofin... I can change external color, my favorite is Talladega Red, or change color of interior - beige. I have to carefully check original paint, maybe it will not be necessary to paint a whole car, just bonnet, left front wing and left doors... In this case it will be better (and cheaper) to change interior colour...

Black on Black is my fav. Red cars are nice but they attract alot of attention. If you want to add some colour this silver (Below) with black would look great. If you two toned it and painted everything below the hood line silver it would look great. The other positive is that this area is also prone to scratches and dings and silver hids eveything. a win win. I do not know whos car this is but it looks great!




http://www.saabcentral.com/phpgallery/albums/Ryans-9-5-Aero/Just_been_washed_003.sized.jpg

misu
31-12-06, 08:05 AM
Yes, red is attractive, but what about yellow?:lol: It is my second very favorite colour. Let people see, that some SAAB is just arriving in the town...

Fact is that I still do not know, what colour I will choose. It is "music of the future".

misu
08-01-07, 01:56 AM
Some new pictures!!!
I just finishing work inside ane engine area and moving down to front wheels. How do You remove 15 years old ABS sensors from a hub? Left one is over already...;oops:

James Bond
10-01-07, 03:50 AM
Mine is yellow (which I actually don't like that much) but people love it.

Also makes the car look "young" somehow!

Agree that the beige interior is more friendly than the black!

Are you keeping the auto box?

misu
14-01-07, 03:42 PM
New photos!
Front wheels assembly complete out!
At home I dismantled all parts and tomorow I will give them for sand blasting and powder coating, so let's wait, how it will look...

misu
26-02-07, 06:54 AM
Hi all,
after almost a month of silence, I have a some new photos for You. They are on saabphotos page, as usually. So look and enjoy!

Matthew
27-02-07, 06:52 PM
Looks like an epic task :o Great photos though! :D

I think that 900 is very lucky that you found it...

misu
28-02-07, 01:21 PM
Looks like an epic task :o Great photos though! :D

I think that 900 is very lucky that you found it...

As I see your project, You do very interesting job too. I have to clean and repair my "Saabine" even more, but Your work shows me a way...
When I looked on instructions for your rust remover, I found, that it is the same chemical, as I use, under another name, of course.
Now I have to think about cleaning of engine area. What would be better, steam or WAP? When I've spoke about sandblasting of the whole car, plenty of people told me not, because this car is not so rusted (except engine bay, as usually) and preparation for painting after sandblasting is really hard, harder than leave it as it is and pay for professional surface preparation. Because it will be painted at Bentley and Lamborgini service center, I hope they know what they do...

misu
15-03-07, 08:12 PM
Some progress. I received sandblasted and powder coated rear brake callipers, so I will complete them during this weekend.

Yesterday I did a new floor isolating pads. Look, how looks original, removed from car:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.16/P3150002.JPG

It was upper side, now bottom one:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.16/P3150003.JPG

And what I did from hydroisolating foil and PUR foam. Upper side:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.16/P3150005.JPG

And botton side:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.16/P3150004.JPG

Matthew
16-03-07, 06:10 AM
Great work on those floor pads. The originals looked horrible :(

Now I have to think about cleaning of engine area. What would be better, steam or WAP? When I've spoke about sandblasting of the whole car, plenty of people told me not, because this car is not so rusted
I have never prepared a surface by sand blasting, but I do know it can cause problems. The blasting can apparently de-stress the metal, causing rippling which then has to be straightened out - but maybe that's just down to bad technique. Removing all the sand must also be time consuming.

If the engine bay is not badly rusted, then I'd either clean up the rust there is using a "stripper" disc (like this (http://www.boatersworld.com/product/377872163.htm)) or by hand using emery paper. Then leave the rest to the painters...

Have you read dougsaab's "You guys and your rust repairs" thread in the 99 Workshop?
http://www.saabcentral.com/forums/showthread.php?t=82007

TheRedBaron
16-03-07, 10:34 AM
Great work on those floor pads. The originals looked horrible :(


I have never prepared a surface by sand blasting, but I do know it can cause problems. The blasting can apparently de-stress the metal, causing rippling which then has to be straightened out - but maybe that's just down to bad technique. Removing all the sand must also be time consuming.

If the engine bay is not badly rusted, then I'd either clean up the rust there is using a "stripper" disc (like this (http://www.boatersworld.com/product/377872163.htm)) or by hand using emery paper. Then leave the rest to the painters...

Have you read dougsaab's "You guys and your rust repairs" thread in the 99 Workshop?
http://www.saabcentral.com/forums/showthread.php?t=82007
Is emery paper synonymous with sandpaper - one of those US/UK words that changes?

misu
16-03-07, 01:31 PM
Yes, it is the same (Czech and he is trying to teach You english:lol: )

misu
16-03-07, 01:45 PM
Rear callipers (almost) done! (Almost, because I need to install steel plug for opposite side of hand brake lever, they havenīt them in stock and fill calliper with brake fluid and seal it just to be sure that no air will enter inside - You know, why...)
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.23/P3180003.JPG

http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.23/P3180002.JPG

misu
23-03-07, 04:19 PM
Well, tomorow I will move my car to the new garage, so work will go faster, I hope. Next week I will send all doors for painting - finally choosed color is Monte Carlo Yellow.

misu
24-03-07, 04:08 PM
My 900 found a new home! Now is at a very clean, comfortable garage, at Prague, near my home. So, I can continue stripping soon, perhaps next week.

On the road...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.24/P3240004.JPG

Home, sweet home...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.24/P3240009.JPG

misu
02-04-07, 02:14 PM
A new photos! Rear axle is out. Just a fuel tank and windscreen to go! (and then cleaning and cleaning and...)

Rear axle "in situ"
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.30/P3290006.JPG

And out!
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.30/P3300008.JPG

Measuring of stickers - I will reprint them (or do You know, where I can buy them?)
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.30/P3300021.JPG

Matthew
02-04-07, 04:05 PM
How will you de-rust the axle?

If you recreated the sticker on a computer, then a printing bureau will be able to make stickers for you. Trickiest bit would be matching the typefaces. Take detailed close-up photos for comparison when you're recreating the text.

misu
02-04-07, 05:18 PM
How will you de-rust the axle?
Sandblasting (it would be finish at wednesday) and powder coating (during thursday, at friday ready for pick up). What You see, is not ready for balsting yet. I had to remove wheel bearings, brakes, brake lines, etc.


If you recreated the sticker on a computer, then a printing bureau will be able to make stickers for you. Trickiest bit would be matching the typefaces. Take detailed close-up photos for comparison when you're recreating the text.
I think Arial will work fine, as usually :p . And if not, I have plenty of fonts to compare and I will use the most matching one. That will be good enough.;)

Matthew
02-04-07, 06:49 PM
Would you consider zinc plating the axle befor powder coating it? I have zinc plating on the brain.

misu
03-04-07, 03:37 AM
Company, what powder coating for me, can give a special zinc paint on parts with resistance 5000 hours inside salt water fog, so they do it for me automatically...

For other parts I have to zinc plated and yellow passivated locks and its screws, some brackets and washers. I have a box with these parts ready to go to galvanising company, perhaps next week. All screws and nuts I can buy, I give new - much better then try to renovate them - rust can destroy them internaly and its strength could be reduced...

Matthew
03-04-07, 06:26 PM
Beautiful foal :cool: I love horses.

Nice saddle mat thing on Griffin :D

misu
18-04-07, 02:42 PM
Well, some new photos. Do You remember photo of rear axle, just removed from car? For quick review here is once again:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.03.30/P3300008.JPG

And how does it looks now:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.04.18/P4180003.jpg


Detail of a right side:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.04.18/P4180001.jpg

Axle and "dishes" are sandblasted and powder coated, hubs are derusted and painted with Hammerite, its bearing were completelly dismantled (into pieces - each ball separated from other), cleaned and regreased with a fresh special bearings grease, brake lines were just cleaned and repainted their splitter was just cleaned (it is from brass). And all screws are new, as usually.
So what do you think? Is it as good as from factory?

Matthew
18-04-07, 03:26 PM
Very difficult to get any component back to factory condition. I think axles are especially difficult as they rust, and you forever lose the smooth surface.

Your axle does look staggeringly better than before. The difference is amazing, and they don't look very pitted from the rust either.

Did the powder coating get into all the corners and gaps?

misu
18-04-07, 05:08 PM
The fact is, that this car lived in Italy, so no snow, no salt, few rains... Sandblasting remove upper layer of material, with all rust, so rest is clean, but a little bit smaller. Because of this, you MUST cover all important holes, screws, etc. And because these surfaces were covered in past, there are no rust on them.
Powder coating is electrostatically applied, so there is no problem with covering each square milimeter with colour powder. This type of paint is also a quite thick, so material, what was blasted off, is replaced with colour - dimensions of part are plus minus the same...
By the way, what your fuel rail and intake manifold? They look like sandblasted, are they, or not?

Matthew
19-04-07, 05:33 AM
Sounds very good! I didn't know that powder coating was applied electrostatically :D

My inlet manifold and fuel rail :evil: They have been "aluminium metal sprayed", a finish which I was told was OE! They didn't tell me say the finish would be that of coarse sandpaper.

I have complained, and am in discussions to get the inlet manifold recovered. The fuel rail's gone for plating: the acid dip will remove the metal spray.

misu
03-05-07, 07:09 PM
Well, some news...

I've finally got seats! After a three months of asking of previous "owner", he found those seats deep inside workshop and gave them to me. First impression was sad, because they had a strange surface, something like a gel, combined with oil spots...
I've tried to do something with a rear one first. I've removed leather upholstery completelly out and put it into wash machine
http://www.zemekoni.org/files/Saab-900-Convertible/2007.05.01/P5010011.JPG
then left for two days to dry and then I apllied a special leather treatment with bee's wax. The surface looks like a new one.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.05.01/P5010012.JPG
Then I've tried to put it back onto its frame. From that frame I've removed an old rusty springs and replaced them with a PUR foam of the same thickness.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.05.01/P5010032.JPG
To put back rest together took me around four or five hours, but... Absolutelly superb!!! A new seat!!!
http://www.zemekoni.org/files/Saab-900-Convertible/2007.05.06/P5060008.JPG

For front seats I am not sure if I will put leather down, or if I will try to clean it on frame, because its back rest, it is a nightmare (to put leather out and put it back). I did it once, many years ago and I still remember it...

misu
07-05-07, 07:24 PM
And here you are detail photos - rear head rests:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.05.01/P5010013.JPG

Left rear seat:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.05.06/P5060009.JPG

Right rear seat:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.05.06/P5060010.JPG

misu
25-05-07, 10:30 AM
I've received some hardware from galvanizing company. All items are originals, removed from my 16 years old car...

http://www.zemekoni.org/files/Saab-900-Convertible/2007.05.22/P5240004.JPG

misu
25-05-07, 10:33 AM
And more "art" work - clock for modified 9000 gauges, what will be instaled into my 900...

All gauges, control lights and computer checked and they work!
http://www.zemekoni.org/files/Saab-900-Convertible/2007.05.22/P5220002.JPG

misu
26-06-07, 07:12 PM
So, car is cleaned and now will stay for a two weeks (vacation). Then I will start work on rustproofing underside, wheel arches, interior and luggage floor.

I have an idea - on whhel arches I want to use paintable underside coating, same as for underside outline of body, when the rest of the underside I will do with nonpaintable one. In interior and luggage floor I will use Rust-oleum Penetrator (after removing of some rust spots, but just surface one, as I already found), then Rust-oleum Alkyton paint, then put sound dampening material and then paintable underside coating. Question is - is necessary paint over that penetrator, may I first use that paintable coating and then sound dampening material, or how would you do this job?

And here some photos:
After removing sound dampening material and before cleaning
http://www.zemekoni.org/files/Saab-900-Convertible/2007.06.01/P6010002.JPG

Luggage floor:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.06.01/P6010004.JPG

Partially cleaned interior area, where top pump is mounted. That orange colour is not a rust, is it reaction of sound dampening material glue and original base paint of body:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.06.14/P6140021.JPG

misu
06-08-07, 01:04 PM
So, after long time of very boring job - cleaning, sanding and repairing of body I've started to paint it, first with antirust treatment - Penetrator from Rust-Oleum.

Here You can see luggage area before...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.04/DSCF0002.JPG

...and after painting:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.04/DSCF0016.JPG

misu
06-08-07, 01:07 PM
Here You can see engine bay area.

Before...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.04/DSCF0009.JPG

...and after:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.04/DSCF0020.JPG

misu
06-08-07, 01:11 PM
And finally, convertible top pump mounting bracket. You can see, as it looked before in some previous post, but here You can see, as it looks now:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.04/DSCF0007.JPG

Now I will apply oversprayable protective coating inside engine bay and luggage compartment and underbody, where a rear axle be mounted. Rest of underbody I will spray with an ordinary bitumen coating.

misu
18-08-07, 02:53 PM
Well, after many days of silence, I have some updates.

I've put anticorrosion layer of oversprayable stone chip, so called "spitter" inside interior area, on bottom part of engine compartment
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.14/P8140004.JPG

and also inside luggage compartment.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.14/P8160001.JPG

I've used this "spitter" for bottom part of chassis, but in this case it was a black one.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.14/P8140008.JPG

misu
18-08-07, 02:57 PM
Now You can compare front wheel arches - before
http://www.zemekoni.org/files/Saab-900-Convertible/2007.01.13/P1130001.jpg


and after
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.14/P8140020.JPG

Space for fuel tank
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.14/P8140015.JPG

misu
18-08-07, 03:03 PM
Today, I've mounted rear axle, except panhard rod (because I forgot it at home...)

All screws are new, tightened with proper torque and treated with copper spray to prevent future corrosion (I hope).

So, watch and enjoy.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.18/P8180004.JPG

http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.18/P8180005.JPG

http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.18/P8180010.JPG

http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.18/P8180013.JPG

Breakin5speeds
18-08-07, 03:23 PM
Well Done:D It's already shaping up to being better than it was when it was new. It's lovely to see someone put so much love in saving one of these gems, I am hoping for the near future that I will be able to save a 85 to 87 SPG (900 Aero in most parts....) to the same level

James Bond
18-08-07, 08:07 PM
I agree - it is wonderful.

AUSSIE900
18-08-07, 09:07 PM
Absolutely Brilliant , Your dedication and attention to detail is amazing . Keep up the sensational work , your car is going to an absolute Gem .. Well DONE !!:cool:

Matthew
19-08-07, 05:17 AM
Stunning work :cool: The engine bay looks fabulous!

I like the finish on the trailing arms. Are they new or were they dip-cleaned/shot-blasted?

Did you have to replace any metal on the driveshaft tunnels?

misu
19-08-07, 06:29 PM
I like the finish on the trailing arms. Are they new or were they dip-cleaned/shot-blasted?
They are sand-blasted and powder coated, like rear axle, brake calipers, etc. They were not too much rusty, they were more dirty... And when I saw them after blasting I knew that powder coating is what they asking me for...
Did you have to replace any metal on the driveshaft tunnels?
No, all panels are original, there were no deep rust, but tons of an old grease and oil, and many old screws and washers...

This car is from Italy, and after five or six years of service it was moved into Czech. From 1998 it was sitting inside many garages only, so very few of salted roads, melted snow and rains. If there is some car, appropriate for renovation, it is this one. As you said, it is a real gem, hidden inside shell of dirt and rust.

woywitka
19-08-07, 07:43 PM
Real nice work there!


Never saw a c900 during my Stay in Prague. Maybe one day I will come back and see yours fly by.

That looks really stunning!

misu
02-09-07, 10:04 PM
Well, show goes on...

Car has rear brakes, but not connected into hydraulic or cables (because of painting, of course.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.25/P8250001.JPG

Here is a other side.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.25/P8250002.JPG

So, let's mount last things on rear axle - wheels and take her outside from garage...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.25/P8250004.JPG

Even a sun came to us...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.25/P8250010.JPG

misu
02-09-07, 10:13 PM
And now, real show begin.

Preparation
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.29/Obraz003.jpg

"Master of spray gun" in action:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.29/Obraz005.jpg

And here we can say "Engine bay - finished" - ready for mounting of front arms, hubs and wheels:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.08.29/Obraz007.jpg

misu
05-09-07, 09:58 PM
Now is time to check all hardware, necesary for mounting front wheels. Among these things is steering rack, an assembly, what is not ready yet. So job for this week is rebuild this rack. I've ordered a repair kit with all seals, bushings, circlips, rings, etc., new tie rod ends and new tie rods. And rubber boots, of course.
Here You can see original state of steering rack
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.01/P8310001.JPG

Here is detail of pinion shaft side (left one here, in Czech rep.)
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.01/P8310002.JPG

Remove rubber boots was easy job, the same, as remove tie rod ends. I've just measured distance between tie rod end and locking nut (on both sides) for rough toe in setting.
What was more difficult, it was removing of tie rods from internal rod, or shaft, or as You name it... You need big force to loose their "nuts" - they are tightened to 90 Nm and stacked.
Next step is to remove side "plug". You have to compress this plug against its spring washer and then remove internal circlip. Here You can see a thin screwdriver, inserted to push this circlip from its groove, then You catch it with a wire hook and remove it. Note, that this circlip is blocked by that side plug, You really must to compress it one or two mm into sterring rack.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.01/P8310004.JPG

misu
05-09-07, 10:39 PM
Show continues...

Now You have to remove damping yoke from pinion shaft. As usually, You need big force to loose its locking nut. When I tried to loose it, I've damaged its sides (service manual shows water pliers as right tool - :lol: ). Never mind, show must go on... Remove bottom plug from pinion shaft and loose its nut - easy
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.01/P8310005.JPG

Remove circlip from upper side of pinion shaft and remove shaft from its housing, then remove bottom ball bearing, seal and spacer.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.01/P8310006.JPG

And now, You can finally remove internal rod with piston. That is easy.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.01/P8310008.JPG

What is really not easy, is removing of internal sealfrom middle of steering rack - opposite seal of that inside side plug. You need really big force to remove it and as a bonus - You MUST NOT damage internal surface of steering rack - it is hydraulic cylinder for steering piston. Even a small damage, and You can go buy a new steering rack...
After that, removing of mounting bushings was a piece of cake...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.01/P8310009.JPG

Now, remove hydraulic tubes from valve to cylinder and You can start cleaning, polishing, or whatever You want to do with steering rack cover.here are some photos before:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.01/P9010010.JPG

misu
05-09-07, 10:44 PM
...and after:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.04/P9040001.JPG

http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.04/P9040002.JPG

http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.04/P9040003.JPG

Story, how I mount everything back will post tomorow, when photos will be uploaded... (If You are interesting about...)

Saab-Daniel
06-09-07, 03:15 AM
Awesome work, definetly keep it coming, really impressive stuff you have going on here...

Daniel.

woywitka
06-09-07, 03:40 AM
unreal work.

Matthew
06-09-07, 05:16 PM
Great photos of the steering rack rebuild. That's of real interest and I don't remember anyone else posting photos before now.

So no special tools required for the rack rebuild then?

Tomarse
06-09-07, 05:28 PM
Amazing! you are doing everything to a very high standard! keep up the good work!

misu
06-09-07, 06:40 PM
So no special tools required for the rack rebuild then?
I had to prepare some tools, but nothing special, what cannot be done at home.
First of all You need some tube, what you will insert between that side plug and tie rod to compress spring washer under that plug, allowing its circlip to be removed. Second tool was necessary to remove seal from middle of rack, You can see it inside service manual, very easy to prepare. That is all.

misu
06-09-07, 06:49 PM
Great!!! :evil:

When I tried to copy photos from card into PC, card crashed... So no pictures of rebuiding steering rack, wait until tomorow, when I send pictures of finally rebuilt rack...

James Bond
07-09-07, 03:57 AM
Just amazing work.


When do we see it?

misu
07-09-07, 03:42 PM
Just amazing work.


When do we see it?

Next spring. Maybe...:roll:

misu
16-09-07, 07:48 PM
So, because I've lost photos from rebuiding steering rack, stage 1, I can offer You words only ...

Rebuiding is very easy, with two important steps. First step is sliding inner seal into main internal rod. You must slide this seal across tooths without its damage. I've used a thin plastic rolled tube, inserted into seal and after that I've slide whole set on rod. Be very careful not to damage seal or steering will leak!
Next step is non returning. You will insert main internal rod into steering rack. When You do it, never try to slide it out again, or You will damage that internal seal I spoke about a couple rows above...
Here You can see a whole rack rebuilt, except tie rods:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.08/DSCF0003.JPG

I've decided to paint tie rods and tie rod ends with Rust-Oleum paint, as it ads some more weeks or months before rust will attack them...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.08/DSCF0006.JPG

Here You can see a whole rack, ready to be mounted into car...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.08/DSCF0010.JPG

misu
16-09-07, 07:56 PM
Well, everything for a front wheels is ready to be mounted, let's mount it!

Freshly painted engine bay is waiting...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.09/DSCF0003.JPG

Upper wishbone on place:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.09/DSCF0009.JPG

Both wishbones ready:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.09/DSCF0011.JPG

Almost all components for front wheel on place, except steering rack, shock, spring and brake:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.09/DSCF0015.JPG

misu
16-09-07, 08:00 PM
Steering rack on its place:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.09/DSCF0022.JPG

Here is detail of steering tie rod end inside wheel arch:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.09/DSCF0016.JPG

Detail of bottom mounting bolts:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.09/DSCF0023.JPG

RickyS
17-09-07, 04:24 AM
Impressive work.

I noticed what appears to be an extra strengthening plate below the upper wishbone. What's this for? Is the original plate not adequate?

What did you use to remove and install the bushing on the front spring seat and the rear spring link?

philb
17-09-07, 07:53 AM
Amazing restoration. One thing I noticed, is that you have no shims behind the top wishbone mounts in the engine bay, for setting the camber. Most cars will need a few in there at least. There are many threads about this subject, you can lookup how many you need to add.

misu
17-09-07, 06:24 PM
Amazing restoration. One thing I noticed, is that you have no shims behind the top wishbone mounts in the engine bay, for setting the camber. Most cars will need a few in there at least. There are many threads about this subject, you can lookup how many you need to add.
I have these shims at home. I will set camber and caster, of course, but this is the very last step, when everything is on the place and car is ready to go. This is the time to set up front wheels (cmaber, caster and toe in).

misu
17-09-07, 06:32 PM
Impressive work.

I noticed what appears to be an extra strengthening plate below the upper wishbone. What's this for? Is the original plate not adequate?

Do You mean that silver thing? It is standard cross member, what also holds skid plate. I forgot to mount it, so I had to remove lower wishbones once again.


What did you use to remove and install the bushing on the front spring seat and the rear spring link?
I've used ordinary two arms puller, the same as You can see on photos from steering rack rebuiding, this is one of my favourite tools, and I've also used threated rod M12 with thick washers together with brass tubes of different diameters - what I found in my workshop and nuts. And plenty of silicone oil (what do not harm rubber, of course)...

RickyS
18-09-07, 04:04 AM
Do You mean that silver thing? It is standard cross member, what also holds skid plate. I forgot to mount it, so I had to remove lower wishbones once again.

No. Not the cross member.

I am refering to what looks like a curved metal plate (silver colour) held on by 2 black tabs/screws(?) attached to the body above the driveshaft hole/tunnel and just below the upper wishbone(control arm).

It shown is these pictures of yours:-
http://www.saabphotos.com/gallery/albums/album649/DSCF0011.sized.jpg
http://www.saabphotos.com/gallery/albums/album649/DSCF0016.sized.jpg

Shan
18-09-07, 10:48 AM
Top work ! :cool:

No. Not the cross member.

I am refering to what looks like a curved metal plate (silver colour) held on by 2 black tabs/screws(?) attached to the body above the driveshaft hole/tunnel and just below the upper wishbone(control arm).

It shown is these pictures of yours:-
http://www.saabphotos.com/gallery/albums/album649/DSCF0011.sized.jpg
http://www.saabphotos.com/gallery/albums/album649/DSCF0016.sized.jpg
That's a "reinforcement", part number 8262354.
Item no.31 in the diagram from the EPC (below) shows the part.

http://www.saabphotos.com/gallery/albums/album696/Reinforcement.jpg

jim_mcghee
18-09-07, 02:58 PM
excellent diagram! Nice work on the rebuild too, excellent work.

misu
18-09-07, 07:02 PM
No. Not the cross member.

I am refering to what looks like a curved metal plate (silver colour) held on by 2 black tabs/screws(?) attached to the body above the driveshaft hole/tunnel and just below the upper wishbone(control arm).

It shown is these pictures of yours:-
http://www.saabphotos.com/gallery/albums/album649/DSCF0011.sized.jpg
http://www.saabphotos.com/gallery/albums/album649/DSCF0016.sized.jpg

Well, as Shan's EPC shows, it is reiforcement, but it also serves as bracket for ABS sensor cable.

misu
18-09-07, 07:12 PM
So now for rest of the work inside front wheel arches...

As a next step, we inserted front springs:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.14/DSCF00011.JPG

Then shock absorbers - Bilstein again:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.14/DSCF0001.JPG

And then brake discs and brake calipers with pads, but they are not connected into hydraulic system (no hydraulic system is in the car):
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.14/DSCF0002.JPG

And next step? Wheels, of course :lol:

misu
18-09-07, 07:18 PM
And when it is on all four wheels, let's take it out...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.14/DSCF0003.JPG

Looks like off-road...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.14/DSCF0004.JPG

Well, maybe I am trying drive this car too soon...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.14/DSCF0007.JPG

My friend Dan. I never would be where I am without his help.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.14/DSCF0008.JPG

RickyS
19-09-07, 04:31 AM
Well, as Shan's EPC shows, it is reiforcement, but it also serves as bracket for ABS sensor cable.

Ah. Its the bracket for the ABS sensor cable. I don't have ABS - so didn't realise what it was.

The part Shan mentioned is the reinforcement bracket on the engine side - I know about that.

Tomarse
19-09-07, 01:43 PM
woo! i gather you are going to do the outside the same proper colour as the engine bay?
Nice to see another montecarlo car! :)

misu
19-09-07, 07:59 PM
Ah. Its the bracket for the ABS sensor cable. I don't have ABS - so didn't realise what it was.

The part Shan mentioned is the reinforcement bracket on the engine side - I know about that.

But this bracket is mounted on screws of this reiforcement. ANd material is really thick. So I have this area double reinforced :cool: .

misu
19-09-07, 08:02 PM
Nice to see another montecarlo car! :)

Two weeks. Give me two more weeks and a new Monte Carlo appears in the world...

misu
25-09-07, 07:44 PM
So, car is in "Mr. Color"s hands...

First of all, he grinded a few repaired areas - all four ends and right side just behind door. Then sprayed a thin layer of anticorrosion protection, followed with a special treatment for good adhesionn of raw, glass filled filler.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.20/DSCF0003.JPG

He works really fast...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.20/DSCF0008.JPG

Fact is, that it needs more filler then we expected...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.09.20/DSCF0010.JPG

And that is all for this moment. Now it will be sanded, then sprayed with a spray putty, then all car will be sanded from gloss to matt, then special filler, yellow pigment (two or three layers) and final two component clear.

In meantime I finished front engine wiring - adaptation into DI/APC. It is fully integrated into car's wiring - like a factory would do. As a last part of this I have to adapt injection wiring, but it is not so hard.

VikingSpirit
25-09-07, 07:55 PM
Why's he fillering that bit when it will be hidden when you put on the Bumper Skirts? :p

In all seriousness an awesome looking restoration there, I look forward to seeing the final result!:D

misu
25-09-07, 11:48 PM
Why's he fillering that bit when it will be hidden when you put on the Bumper Skirts? :p


There were problem with overal shape above bumper, so he had to do a whole corner. Do not forget, it was Italian car, so both rear corners were a little bit damaged :cool: (You know, how Italians park...)

PS.: All Italians here in forum are exceptions, of course...:cool:

philb
26-09-07, 05:30 AM
In meantime I finished front engine wiring - adaptation into DI/APC. It is fully integrated into car's wiring - like a factory would do. As a last part of this I have to adapt injection wiring, but it is not so hard.

You can't write that and then not post pictures and details, come on!

misu
26-09-07, 07:08 PM
You can't write that and then not post pictures and details, come on!
Well, fact is that You will see absolutelly nothing from any pictures. Only connector housing for APC unit is a little bit bigger, there are not wires for ignition coil and distributor sensor, but there is a new loom for DI cassette, one connector for crankshaft sensor (what is the same like with EZK ignition) and one more three pin connector for connect with injection wiring...
I could not made photos during soldering, because I needed all my hands and legs, even a mouth too, to hold and set everything...

Ok, I will make some final photos tomorow...

misu
03-10-07, 02:19 PM
I promissed photos, but I have nothing yet, so sorry.

Car is inside painter's garrage, so I have no visual contact with it, just phone calls... Because of very hard surface of original color and sprayable filler it looks that it will need one more week before it will be painted.

In meantime, I work on LH wiring, this is last wiring loom what needs to be cleaned, and rewired (from LH 2.2 into 2.4 and from distributor into DI). Change into DI is very simple (for this wiring), just add some more wires from ECU - I need one new 3-pole connector. But this wiring shows the most ageing of isolating material from all cars wiring looms. All plastic sleeves, covering wires, are very brittle, cracked and missing. Fortunatelly (and surprisingly), rubber bushings of connectors, are all intact. So I had to dismantle each connector, clean its housing, clean that rubber bushing, remove an old protecting plastic sleeve, clean isolating on wires, put a new, soft sleeve and assemble it.

misu
08-10-07, 01:38 PM
Car is yellow!!!

During saturday it changed from black into Monte Carlo yellow. Enjoy photos:

Car is transported into painting facility:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.06/DSCF0022.JPG

Now is inside paiting booth, carefully covered with paper and masking tape:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.06/DSCF0034.JPG

Painted with anticorosion treatment and surface preparator:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.06/DSCF0035.JPG

From another angle:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.06/DSCF0037.JPG

misu
08-10-07, 01:46 PM
One detail, just to see, how well it is done:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.06/DSCF0039.JPG

Painting with final color started. Pigment is PPG envirobase, two coats:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.06/DSCF0046.JPG

Both two coats done:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.06/DSCF0052.JPG

And one detail again:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.06/DSCF0060.JPG

misu
08-10-07, 01:52 PM
Final step is clearcoat, two layers again. It is also PPG, Clearcoat number 8109, one of the most durable clearcoats from PPG, better is Ceramiclear, but it is VERY expensive...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.06/DSCF0066.JPG

Next day morning. Car is home again, perfectly painted and ready to be assembled back. Windscreen frame will be painted later, perhaps next week (when clearcoat perfectly dries).
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.07/DSCF0003.JPG

Also from another angle. Isn't it wonderfull?:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.07/DSCF0001.JPG

AUSSIE900
09-10-07, 09:18 AM
I remember the first day I saw pictures of this car , and thinking .. BOY ... does this guy have his work cut out , The car is looking absolutely sensational , It is an absolute testament to anyone here of what can be achieved ,

A sincere well done and it keep up the fantastic work ...

Your vert will be the pinnacle we can all aim for :D

RickyS
10-10-07, 05:48 AM
Windscreen frame will be painted later, perhaps next week (when clearcoat perfectly dries).

What's the reason for not painting the windscreen frame when the rest of the car was sprayed?

It looks great - if you like Monte Carlo yellow.

James Bond
10-10-07, 07:27 AM
Monte Carlo yellow is a great colour!

Ask me why!

misu
10-10-07, 09:26 AM
What's the reason for not painting the windscreen frame when the rest of the car was sprayed?

It looks great - if you like Monte Carlo yellow.

Because it has to be covered with matt clearcoat, so You need the rest of the car perfectly dry, before You will mask frame.

saabismi
10-10-07, 11:21 AM
Monte Carlo yellow is a great colour!

Ask me why!

Ok then:Dwhy??



on another note..the car looks just...stunning;)great job!

Shan
12-10-07, 12:07 PM
Ok then:Dwhy??

on another note..the car looks just...stunning;)great job!
Here's why :

http://i12.photobucket.com/albums/a245/woywitka/saab_900_convertible_1992_01_s.jpg

:)

Matthew
12-10-07, 12:26 PM
I really think Misu's finished car will look that good :D

misu
12-10-07, 02:47 PM
Yes, yes, yes. It will be almost the same, except that big spoiler, because I have just a small one (for this moment). But wheels will be the same, during monday I will get these rims in exchange of new set of winter Nokian tyres... And price? Better then perfect (for me)...

misu
12-10-07, 02:59 PM
By the way, I've just ordered an original labels from Saab. All labels from engine bay area, warnings from interior, tyre presure, body color, etc... All will be a new.

And just for case that it will not come, here are some "home made":
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.11/DSCN3577.JPG

TooMany2cvs
12-10-07, 03:03 PM
By the way, I've just ordered an original labels from Saab. All labels from engine bay area, warnings from interior, tyre presure, body color, etc... All will be a new.

And just for case that it will not come, here are some "home made":

The little details that make all the difference...

aerobar900
13-10-07, 12:36 AM
Where do you order the labels from? I'll need a set.


Thanks

misu
13-10-07, 07:32 AM
Where do you order the labels from? I'll need a set.


Thanks
I do not know... It ordered one friend from Slovakia, he said he ordered some these labels with no problem from someone, so I asked him to order some for me. If You will send me cat. numbers, I can ask him to add them into my order.

aerobar900
13-10-07, 11:21 PM
PM sent. (need 10 characters)

misu
14-10-07, 06:33 AM
For all of You, if You want these home-made decals, tell me and I will send You a word document, what You will print in laser printer on selfstick film, that's all.
If You want label, what is not prepared yet, send me good photo, with its dimmensions (width and height), I will make them and send them. or I can put them somewhere, so who wants, can download them...

Honkey
14-10-07, 10:15 AM
If you could upload them to http://www.megaupload.com/ and then post the link in here that would be great, I wouldn't mind having that kind of thing kicking around incase I ever want fresh stickers :cool:

TooMany2cvs
14-10-07, 11:00 AM
If you could upload them to http://www.megaupload.com/ and then post the link in here that would be great, I wouldn't mind having that kind of thing kicking around incase I ever want fresh stickers :cool:

Sounds like a good idea - or maybe have them downloadable directly from the Features area of this site? I would suggest doing them as a PDF rather than a DOC, though, to help minimise the risk of fonts not being available etc.

misu
14-10-07, 08:16 PM
Sounds like a good idea - or maybe have them downloadable directly from the Features area of this site? I would suggest doing them as a PDF rather than a DOC, though, to help minimise the risk of fonts not being available etc.
OK, I will convert it and upload it. Give me one or two days, please.

misu
15-10-07, 08:44 PM
Building started!

After one year of dismantling, cleaning, etc, I can built it back!
So as a first step, we glued sound damping material (3M). Interier area:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.13/DSCF0008.JPG

And luggage compartment:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.13/DSCF0009.JPG

Then we riveted some stuff into engine bay - heat shield, wiring loom channels, etc. Also some rubber plugs, grommets, etc.:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.13/DSCF0001.JPG

I've re-routed fuel lines and instaled a new fuel filter - banjo fitting were sprayed with cooper grease after tightening, for an easy removing in future:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.13/DSCF0011.JPG

misu
15-10-07, 08:47 PM
You can see, how they are routed inside an interior, together with brake pipe:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.13/DSCF0007.JPG

And this is the last piece for today. Do You see our "underground" logo? Two airscrews are not enough...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.13/DSCF0019.JPG

RickyS
16-10-07, 06:48 AM
Great photos.

I'd be interested to see how you seal up the rear light cluster. That area is the cause of leaks in older cars. Have you new seals or are you reusing the existing seals?

TooMany2cvs
16-10-07, 06:55 AM
banjo fitting were sprayed with cooper grease after tightening, for an easy removing in future:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.13/DSCF0011.JPG

It's great to see that you're building this car to be used and maintained rather than just be polished and looked at...

misu
16-10-07, 07:18 PM
Great photos.

I'd be interested to see how you seal up the rear light cluster. That area is the cause of leaks in older cars. Have you new seals or are you reusing the existing seals?
I do not know yet, it is question for next day, when I will try fit and eventually mount these clusters. I use existing seals, because they look OK, but maybe I will use some silicone from tube... We'll see...

misu
16-10-07, 07:19 PM
It's great to see that you're building this car to be used and maintained rather than just be polished and looked at...

A car, what is just for exhibitons, is not a real car, it is just a museum exhibit... Cars must ride. As much as they can. This is what they are built for...

VikingSpirit
17-10-07, 08:49 AM
Argh! Please paint behind the rear seat!:cry: My 900 went really rusty round there!:o

With the car apart this is your chance to paint all the areas that saab never bothered with first time round and make it more resistant to rust!

Really great Job aside from that though Misu, this car is going to look stunning..:cool:

misu
17-10-07, 07:24 PM
Argh! Please paint behind the rear seat!:cry: My 900 went really rusty round there!:o

With the car apart this is your chance to paint all the areas that saab never bothered with first time round and make it more resistant to rust!

Really great Job aside from that though Misu, this car is going to look stunning..:cool:
I've painted it. With special anticorrosion treatment (that's that light grey color) and bottom parts with oversprayable antichip underbody over this layer (medium grey). So rust have a very little chance (if any) to attack. :cool:

( http://www.saabcentral.com/forums/showpost.php?p=1033463&postcount=42 and forward)

misu
18-10-07, 07:34 PM
Show continues...

Most important peddal on place:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.15/DSCF0001.JPG

Just mounting handbrake. Note its lever is with leather now:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.15/DSCF0002.JPG

Opposite end connected into calliper:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.15/DSCF0007.JPG

Next step, vacuum tank (bomb) and...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.16/DSCF0003.JPG

misu
18-10-07, 07:38 PM
Wiring!!! Main loom across a whole car, just layed and ready to be exactly fixed. Here around centre console:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.16/DSCF0007.JPG

Detail of firewall mounting:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.16/DSCF0009.JPG

Deatil of routing behind rear seat:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.17/DSCF0013.JPG

And that's all for today. But friday and a whole weekend ahead...

misu
23-10-07, 08:42 PM
So I've built a little bit...

Rear end almost finished (except bumper, what I have not yet):
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.19/DSCF0016.JPG

Detail of right light cluster:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.19/DSCF0017.JPG

Interior area - gear selector lever and ignition lock on place, wired:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.19/DSCF0025.JPG

Brake peddal is mounted, what means...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.22/DSCF0011.JPG

misu
23-10-07, 08:50 PM
ABS pump assembly, like all other components and wiring is mounted, too:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.22/DSCF0002.JPG

(Previous photo is from mounting all components together, so some brackets and spacers are missing, and wiring is not exactly, where it should be, so when everything is on place, it looks like this:)
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.22/DSCF0010.JPG

ABS fusebox and side flasher:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.22/DSCF0012.JPG

I've also mounted vacuum pump and switch for cruise control:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.22/DSCF0009.JPG

That black box in front is not just APC, it is DI/APC! Yes, this car has fully integrated DI in its wiring...

KurBads
24-10-07, 03:46 AM
Man ... I wander if there will be any unrestored part left in that car when you finish? I see that you have restored/repainted/conditioned everything, e.g., your ABS distributor or that black wiring loom channel on the firewall ...

I bet you have spent more time in your garage than at home ...
You mentioned that it`s ~ one year that has passed since the beginning, I just wander what it really takes timewise and cost-wise to get to such a result ...

Really great job, the best and most complete restoration I`ve seen so far ...
This is dedication!!!

James Bond
26-10-07, 06:16 AM
Yes, but no news for 2 days!


What's happening?

saabismi
26-10-07, 09:29 AM
Im guessing hes working on the car as we speak....but come on we need information:D

misu
26-10-07, 01:53 PM
Yes, but no news for 2 days!


What's happening?
I was sleeping, and working as all other people...
Now I have to restore hydraulic system for conv. top. Both pistons are restored (with all O-rings replaced), and I am currently working on pump. Its motor is full of rust, do not know yet, if it will even work. But rotor looks fine, no signs of broken wires, or damaged commutator, etc. Main trouble was to clean that rust, because there are magnets inside, so all rust was "glued" on them...

Tomorow we will work on car, plans are: mount dashboard beam with all its wiring, and fill brake system.

James Bond
29-10-07, 03:02 AM
Where are you in Czecho?

I'd love to see her when finished.

Matthew
29-10-07, 02:14 PM
It'd be fantastic if you could bring this car to the Saab Festival in 2008 :D Bit of a trek though...

Awesome work :cool: Your dedication is inspiring :D

misu
29-10-07, 07:36 PM
Where are you in Czecho?

I'd love to see her when finished.
In Prague.
What are You doing in South Africa? You were in Lisbon a couple of weeks ago...

misu
29-10-07, 08:47 PM
It'd be fantastic if you could bring this car to the Saab Festival in 2008

And when this event will be? And where (exactly)?

misu
29-10-07, 09:29 PM
In Prague.
What are You doing in South Africa? You were in Lisbon a couple of weeks ago...

Oh sorry, Mr. Bond, I've missed Your nick...
No more questions...

misu
29-10-07, 09:42 PM
New photos!

During sunday we finished brakes, connected all pipes, filled with fluid and bleeded. We had troubles with rear ones, because we had not prepared all wiring to switch on brake pump, so we did it with compressed air... Anyway, front brakes are working perfectly, rear brakes we will do when all electric systems will work...
But we mounted dashboard beam, with all dashboard items! Tons of wires, connectors, hoses, tubes, pipes, etc. Look and enjoy!
Overview from rear of the car:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.29/DSCF0009.JPG

Closer view from right side:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.29/DSCF0011.JPG

And detail from driver's side:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.29/DSCF0002.JPG

Just a very small part of al wiring, what are waiting for me... Connect it, check it, forget it...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.29/DSCF0003.JPG

Palmer1980
29-10-07, 10:00 PM
Simply wonderful.

misu
29-10-07, 10:03 PM
Here You can see fresh air intake, together with AC evaporator and wires, waitnig to be connected into main +pole distributor:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.29/DSCF0001.JPG

ABS fusebox and steering fluid reseivoir finally mounted:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.29/DSCF0005.JPG

At rear end I've mounted filler neck:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.29/DSCF0006.JPG

You can see, all hoses are new, clamps too. They are ABA Sweden, like originals. There are solenoid too, for locking filler cover, like on 9000. ANd last interesting thing - rubber profile around boot opening is new. I found company, what sells these special profiles - www.gumex.cz (http://www.gumex.cz)
http://www.zemekoni.org/files/Saab-900-Convertible/2007.10.29/DSCF0008.JPG

James Bond
30-10-07, 05:40 AM
Misu,

I am a gypsy - I like to live in Lisbon, but have started a new job in Johannesburg.


I'm thinking of bringing the yellow fellow here, if they will let me bring it in to the country!

It is the same as yours.

My brother lives in Prague. When yours is ready, it will give me another reason to visit Praha ...... :)

Peter

RickyS
30-10-07, 07:57 AM
ANd last interesting thing - rubber profile around boot opening is new. I found company, what sells these special profiles - www.gumex.cz (http://www.gumex.cz)

That is a good find. I couldn't find an aftermarket supplier of door or boot seals. Some of these seals are still available from Saab dealers, but are very expensive in the UK.

Have you found a supplier for replacement window seals? The exterior seals rust, and they are no longer available from Saab.

Matthew
30-10-07, 03:30 PM
And when this event will be? And where (exactly)?
Trollhattan, Sweden in June 2009. Prague to Trollhattan is 722 miles.

woywitka
30-10-07, 03:52 PM
wow, just incredible


wait

only 2 pedals.....is this an automagic?:o

misu
30-10-07, 10:51 PM
wow, just incredible


wait

only 2 pedals.....is this an automagic?:o
Yes, after many dreamless nights I've decided to implement autotranny. For city driving it is much better, and I do not suppose I will want to drive more than around 110km/h with open top...

James Bond
31-10-07, 07:29 AM
Mine's an auto - nice around town but boring on the open road!

James Bond
07-11-07, 06:20 AM
By the way, you can drive comfortably up to 140 km/hr or so. Even better with a wind deflector fitted.


How is progress?

misu
07-11-07, 02:05 PM
How is progress?

Slow. Very slow. Now it is very boring, because I have to check every electrical system, plug it into whole "net" and check, if all these systems work together, as they should.
In menatime I cleaned folding top mechanism, unfortunatelly I cannot renovate it as I would like to, because it is an american system, with UNC and UNF screws and nuts, what are unpossible to buy here. Also many really BIG rivets, with plastic bushings, so I cannot powder coat it (because a high temperature during melting powder), so I just clean it, remove old grease and put a fresh one, and that is all.
Hydraulic system is in perfect condition now, with new O-rings, freshly filled with hydraulic oil, its pump motor is also cleaned and freshly greased and all this sytem works as a new one.
During saturday I will mount something into car, so You will see some new photos...
By the way, how dangerous is to mount an airbag steering wheel without airbag connected into SRS ECU? I have leather airbag steering wheel in top condition, but this car is not SRS equipped.

Honkey
07-11-07, 11:12 PM
From what I've seen/heard you can take the airbag module out of the wheel itself (same way you would exhange it for a new one after 10 years).

TooMany2cvs
08-11-07, 04:09 AM
From what I've seen/heard you can take the airbag module out of the wheel itself (same way you would exhange it for a new one after 10 years).

The centre boss of the wheel's going to be basically the airbag module. You can remove it, sure, but it's going to leave a fairly ugly wheel unless you replace it with something else, and I doubt there'll be a direct non-airbag equivalent centre section.

I don't think there's any great risk from an airbag wheel not connected to the electronics, though the doom'n'gloom merchants always reckon they could go off randomly even sat on a shelf - strikes me that the risk of that happening without the electronics connected is no higher than with, probably lower.

misu
08-11-07, 05:21 AM
OK, I will leave it as it is... Another problem solved. Thank You!

Now I have problem with tranny. Guy, who promised me one here in Czech, forgot to tell me, that he has not front cover from it and also freewheel is missing, top cover too and as a last thing - throttle cable and housing (what are different from manual). And cover of gear selector lever, together with handle...
:evil: :evil: :evil:

James Bond
09-11-07, 05:43 AM
Sorry I can't help.

I'm going to change my auto for a manual one day and you will be welcome to the old box.

One day! :)

misu
20-11-07, 08:05 PM
Show goes on!

I've finally got a distribution box for positive supply (in good condition - with cover), so I've mounted it:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0001.JPG

I've got a main negative cable (blue one) too:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0002.JPG

Both cables ready, so let's put a battery in, so I can test all electrical systems with full power:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0003.JPG

misu
20-11-07, 08:26 PM
And I will need many amperes and volts soon, because I've decided to mount folding top!
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0006.JPG

http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0005.JPG

After that, I've preliminary set up its parking position, etc. and started to put its hydraulic into "fuselage". Both cylinders were dismantled, cleaned, its internal O-rings and seals replaced, pump motor was dismantled, "derusted" (absolutelly crazy work, there are two big magnets inside, so that internal rust powder is magnetic!), system was filled up with fresh hydraulic oil, bleeded and intensively tested for smooth operation and leaking.
Pump is on place already, now I am trying to put right cylinder in:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0004.JPG

misu
20-11-07, 08:37 PM
A few minutes later - both cylinders on place, cable connected, time to put relays in and connect cylinders to top mechanism...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0007.JPG

Here You can see left cylinder, mounted, but not connected. All I have to do, is let go electricity in and move piston up.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0008.JPG

When I've connected also an opposite side, moment of truth came to me. Will it work?

Yes, it will!!! And movement is absolutelly smooth and accurate!
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0014.JPG

Next time about mounting doors and boot lid...

James Bond
21-11-07, 01:08 AM
Brilliant.

Did you try to find the "correct" battery?

I have one like yours and the heatshield touches the turbo.

This does not seem to upset bthe battery itself, but I suspect that some vibration is passing from the engine to the body of the car. One fix is to use a sealed boat battery which is narrower.

How is your auto box now?

TooMany2cvs
21-11-07, 02:30 AM
When I've connected also an opposite side, moment of truth came to me. Will it work?

Yes, it will!!! And movement is absolutelly smooth and accurate!
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.10/DSCF0014.JPG

That looks a little bit close to the garage roof... Bet that caused a moment of "Oh, gawd, no, please..."

Did you try to find the "correct" battery?

I have one like yours and the heatshield touches the turbo.

I had the exact same problem at the weekend...

This does not seem to upset bthe battery itself, but I suspect that some vibration is passing from the engine to the body of the car.

I've not (luckily) got any increase in vibration noticable, but I suspect the turbo flange is busy carving a recess for itself in the heat shield.

James Bond
21-11-07, 04:39 AM
Excatly.


One of the retaining nuts / studs carves a nice recess in the shield ......

misu
21-11-07, 06:20 PM
That looks a little bit close to the garage roof... Bet that caused a moment of "Oh, gawd, no, please..."

Do not worry, those tubes are BEHIND folding mechanism working area.

misu
21-11-07, 06:31 PM
Brilliant.

Did you try to find the "correct" battery?

I have one like yours and the heatshield touches the turbo.

This does not seem to upset bthe battery itself, but I suspect that some vibration is passing from the engine to the body of the car. One fix is to use a sealed boat battery which is narrower.

How is your auto box now?

I've found it on Banner pages. They offer three different types and one my friend (who drives Saab 9-5), who is working in this company, told me that this one is the best choice, even it has terminals in opposite arrangement (what is, unfortunatelly, more common) - positive one at right, if you look from side, where they are. Old Saabs preffered different arrangement, positive left, so terminals were closer to wheel arch, not to heat shield.
Anyway, I'll see and eventually change battery to another one...

For autobox... I've decided to buy so called "complete one", even with missing parts and find those missing covers somewhere. The front one I have already and other will find too. I've also decided to order a new torque converter from ebay - 199,-USD, NIOB (new in original box). And what is serviceable inside, I will change too. Like seals, O-rings, clutch plates, bands, etc.

misu
27-11-07, 01:41 PM
Well, time for mounting doors and lid...

Here are some photos from mounting boot lid and doors. First, we've mounted lid. Work for four hands, one spanner and one hour...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.17/DSCF0001.JPG

But it works as new one:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.17/DSCF0008.JPG

Doors came next... Setting was much easier and final efect is superb:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.17/DSCF0002.JPG

misu
27-11-07, 01:52 PM
OK, both doors installed...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.17/DSCF0005.JPG

Let's mount lock and outside handle (with all sealing hardware)!
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.22/DSCF0001.JPG

Look inside is more interesting. You can see lock mechanism, partially connected (because of remote locking there is also lock motor here, and key switch, waht is not connected yet) Also there is window lift, but without window, and unconnected:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.22/DSCF0002.JPG

misu
27-11-07, 02:03 PM
Locking pin. Simply photo, but carefull work with setting it, so door can be closed very easy, but without any play...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.22/DSCF0004.JPG

So, even inside handle is on place. Finally I've decided not to connect that key switch, because it would send alarm system into indefinable state. In case of alarm or battery malfunction, I can unlock door by key thru mechanical connection, without central locking feature.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.22/DSCF0005.JPG

Fits fine...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.22/DSCF0007.JPG

misu
27-11-07, 02:12 PM
Ok, let's go for second door. Lock cylinder:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.22/DSCF0008.JPG

And this is all, because is too late and too cold...
But as a bonus, two pictures of front crossmember.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.22/DSCF0011.JPG

Cross member is sand blasted, then coated with special antirust zinc treatment (stay fine more than 5000 hours inside of salty fog) and then powder coated. All screws and hinges and lock hardware is fresh zinc coated, and yellow passivated.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.22/DSCF0010.JPG

DanF.
27-11-07, 02:16 PM
awesome work.. outstanding. inspiration for us lazy c900 folks.

misu
05-12-07, 01:48 PM
A couple of days left, and Saab has "eyes". Right one...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.03/DSCF0038.JPG

...and left one:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.03/DSCF0039.JPG
It is because we will setting up bonnet (or hood), so I need finished front shape of the car... All lights are working - tested, of course.

misu
10-12-07, 09:44 PM
Well, last time I've finished with passenger door lock, so let's continue on that side. A quick look inside that door - there are just a light and cables there...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.11.22/DSCF0009.JPG

One hour later, all door hardware mounted:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.03/DSCF0041.JPG

As You can see, there is a mirror too. So just glass is still missing. But this is work for another day...

I've mounted also a driver's mirror:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.03/DSCF0040.JPG

So, dorrs almost finished, next step is boot/trunk lid. There are not only lock mechanism, but also lights for registration plate:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.03/DSCF0047.JPG

misu
10-12-07, 09:57 PM
Work was quite easy and after a couple of minutes it looked like this:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.03/DSCF0046.JPG

Well, there is nothing to see, when boot is closed...
Once again, boot (trunk) open:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.03/DSCF0048.JPG

After that, I've glued a pocket for top behind rear seats:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.03/DSCF0042.JPG

Crazy work. There are too much of material and I had no idea, where put it... I hope it is as it should be...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.03/DSCF0045.JPG

So, it is all for this moment, next time I will mount two straps - covers for folding mechanism, rear windows, and some other things...

James Bond
11-12-07, 03:46 AM
Beautiful work.

ejenner
12-12-07, 07:43 AM
Just a note to say well done... it looks great.

If you need any help with the DI/APC - I've done it before so you can ask...!

Shutter-wheel has to have the centre slightly enlarged and you also need to enlongate the holes for
the mounting screws. You have to be accurate so the disk is mounted centrally. If not then
the disk will clip the sensor and destroy it pretty quickly.

http://www.red-green.co.uk/web/photos/gallery/99t16/full/99T16_DI_003.jpg

http://www.red-green.co.uk/web/photos/gallery/99t16/full/99T16_DI_004.jpg

misu
13-12-07, 06:32 PM
Just a note to say well done... it looks great.

If you need any help with the DI/APC - I've done it before so you can ask...!

Shutter-wheel has to have the centre slightly enlarged and you also need to enlongate the holes for
the mounting screws. You have to be accurate so the disk is mounted centrally. If not then
the disk will clip the sensor and destroy it pretty quickly.


Thank You for Your offer. But this is song of far, far future... Now I have serious troubles with bonnet. The one I've tried to set, was too rusty for my paint master, that he said he will not paint this scrap of rust, so I found another one, but I have no time now to set it up, so it looks, that it will continue to the next year...

About shutter wheel: Isn't it better to make more holes into original one? I mean into ordinary EZK wheel? With dremmel it should be pretty easy and difference of these holes plus minus 0,5 mm against calculated position and size shouldn't be a problem, I think...

ejenner
14-12-07, 02:22 AM
Maybe that would be ok but if you get it wrong it will change the ignition timing :lol: I'd be interested to know if it was just the holes to drill and the slot that needs cutting out or if you have to do more or less than that?

nbell
14-12-07, 04:53 PM
Just found this thread and read it with great interest. Misu you are doing a PHENOMENAL job. What a dream, to have the time and money to stripdown a 900 and rebuild 'as-new' car...very very :cool:

Dare I ask how many crowns/euros/dollars you estimate the car will cost by the time you finish?

misu
17-12-07, 01:16 AM
Dare I ask how many crowns/euros/dollars you estimate the car will cost by the time you finish?
Really much. That's all, I can say. Because if I would count it exactly, or even approximatelly, I would ask to become a psychiatric patient...

misu
29-12-07, 08:58 AM
Hi everybody, I am still alive...

After many days of silence, I have some news. First of all, car moved again, now to its final home inside garage complex just front of my house. Those garages are a little bit bigger then doghouse, but it is home. And when I need to work hard, I can push car into corridor, where is space more than enough...

http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.29/DSCF0119.JPG

misu
29-12-07, 09:28 AM
Those two straps of cloth, what should protect top cloth from damage from folding mechanism, are on place already.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.29/DSCF0123.JPG

Those pieces of silver tape are covers for already damaged protecting straps...
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.29/DSCF0122.JPG

Two details can be seen here: Washer bottle and AC receiver/dryer, with a new hose.
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.29/DSCF0124.JPG

misu
29-12-07, 09:41 AM
Now, move to luggage compartment... Its side carpets are trimmed from hatchback car, because I have not original from sedan, or even convertible... But those from hatchback are usable, with good knife and glue...
You can see, sides are almost done, and top cover is near final mounting its top edge. Comp. light was tested, of course, and is working fine, together with its mercury switch (hi, ecologists):
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.29/DSCF0121.JPG

Look at right side:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.29/DSCF0120.JPG

One scroll of mouse for you, a couple of minutes for me, and that top cover is finally mounted:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.29/DSCF0125.JPG

misu
29-12-07, 09:46 AM
Last work for today - rails for bumper extensions. Here You can see front one:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.29/DSCF0127.JPG

And here are rear one. They are sprayed with zinc protecting spray, to prevent oxidization of aluminium and rust of steel:
http://www.zemekoni.org/files/Saab-900-Convertible/2007.12.29/DSCF0128.JPG

Most of You know, what will be next step. For the rest - I will mount bumpers. Rear one first, then front one, but that one just for test only, I have many thing to do at front end...

misu
10-01-08, 09:38 PM
Happy New Year!!! (Hope it will be...)

Last year I've finished just before bumpers to be mounted. So it was a first task this year:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.09/P1090020.JPG

Bumper extensions came second:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.09/P1090021.JPG

Front end. Trying to mount AC condenser. It is a new stuff:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.09/P1090022.JPG

AC condenser from engine side. I have to clean my camera...
And I have to solder APC connector on those free wires...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.09/P1090023.JPG

misu
10-01-08, 09:42 PM
Sun shields and interior light mounted and checked. I've replaced an original passenger mirror (just a chrom plated sheet of metal) with real mirror (glass and silver):
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.09/P1090024.JPG
(Well, I really, really HAVE to CLEAN my camera...)

I've tried to mount interior covers of A-pillars. But unfortunatelly they were deformed, so it was necessary to glue them to pillars with a rubber glue. Hope it will help...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.09/P1090026.JPG

Let it cure for two or three days:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.09/P1090025.JPG

woywitka
10-01-08, 11:03 PM
Lookin good!


I like how you kept the A/C:cool: . Everyone does away with it.

I take it you are going with R134a instead of R-12? Let me know how much of a difference a new Condensor makes, I'm awlays curious to know!

Honkey
11-01-08, 05:58 AM
Woah man this is some seriously maticulous work your doing :)

Just wondering though dude.... you must already be broke retoring this car, but dont you think you could muster up some money for an air flow kit?

Cant wait for more pics!!!

misu
25-01-08, 02:00 PM
So,

work goes on...
A-pillars are finished, glue cured, time for dashboard...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.18/P1180001.JPG

Now details from left side...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.18/P1180002.JPG

...thru middle...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.18/P1180003.JPG

...to right side:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.18/P1180007.JPG

misu
25-01-08, 02:16 PM
Let you see an overview of whole dashboard. Note very poor glove box wood sheeting. It must be replaced with a much better one...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.18/P1180011.JPG

Almost one week is between these two pictures. Dashboard with control panel bezel, partially connected (light switch, fog light, mirrors, all three knobs - fan speed, temperature and air distribution, warning flasher and rear window and mirror defogger switch. All switches are working and its systems are tested.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.25/P1250019.JPG

With help of electric drill I've tested even cruise control - drill connected to speedo cable rotating around 50km/h, inginiton ON, gear selector on D, cruise switch ON, set speed and then I've watched, what vacuum servo will do. It vacued and pull throttle pedal a little bit. Then I've tried to slow rotation down, and servo pull pedal even more. Then tried to speed rotation up, and pedal was released.

As you can see, also carpets are at place, waiting for screws, etc...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.01.25/P1250021.JPG

ejenner
25-01-08, 02:47 PM
Looks like it's going very well. I'm particularly interested in the installation of the 9000 clock-set... How similar are the electrical connectors... did you have to do much work on them to get it to work?

TheRedBaron
25-01-08, 03:00 PM
Looks like it's going very well. I'm particularly interested in the installation of the 9000 clock-set... How similar are the electrical connectors... did you have to do much work on them to get it to work?http://www.saabcentral.com/forums/showthread.php?t=96790

Good work Misu, I'm amazed how much you've gotten done in a seemingly short time!

misu
26-01-08, 06:36 AM
...installation of the 9000 clock-set... How similar are the electrical connectors... did you have to do much work on them to get it to work?
Display is new, I've used just internal mechanism and pointers. But the rest is homemade - drawing software (Tommy cad draw) and laser printer. Concerning connectors, You need just three wires - ground, always live and light. Original control panel from 900 has all three wires, what You need is to cut them from connector and resolder them... Very easy instead...

ejenner
26-01-08, 12:51 PM
Did you remove MPH letters from speedo or did it never have MPH markings?

misu
27-01-08, 05:14 AM
Speedo is from some Switzerland, or Italy imported car, so i has just km/h, so nothing was cleared. By the way, to remove something from speedo, tacho, etc. is very difficult, it is much better to print out a new foil (with cleared desired things), spray it with a good matt clearcoat and put this foil above original, or - much better - spray that foil from inner side with white, then very carefully with help of light from front side with good brush paint all surrounding area with black, so backlight will not come across black area of meters (printer ink do not cover enough against original, or any brighter backlight).

Matthew
27-01-08, 03:55 PM
This is fantastic work :D

One thing I'm impressed with is how you've kept track of all the parts. There must have been hundreds!

mmustillo
29-01-08, 07:31 AM
Hi,

Who is the person that is in CZECH REPUBLIC?

I am from Prague but I live in Australia now! :-)


Mati :-)

misu
29-01-08, 09:29 AM
Hi,

Who is the person that is in CZECH REPUBLIC?

I am from Prague but I live in Australia now! :-)


Mati :-)
Hi,
or, better to say:
Cau, jak se tam mas? No jo, jsem z Prahy a pokud chces trosku pokecat v cestine, zkus www.parkoviste.koukej.info (http://www.parkoviste.koukej.info) , najdes me tam pod stejnym nickem.

For the rest, who will try to read it - it was a czech language...

TooMany2cvs
29-01-08, 09:42 AM
For the rest, who will try to read it - it was a czech language...

<dredges memory>
Dva pivo, prosim.

misu
29-01-08, 10:22 AM
<dredges memory>
Dva pivo, prosim.

Dve piva, prosim - it is correct...

Matthew
30-01-08, 04:19 PM
I've just read through this entire thread and once again am just amazed at the dedication and quality of work. You've given me a standard to aim for with my own efforts.

Can you tell me more about the stone-chip coating you applied to the engine bay?

misu
31-01-08, 01:15 PM
Can you tell me more about the stone-chip coating you applied to the engine bay?
One picture is more than thousand words:
http://www.motipdupli.cz/Data/img/_ikony/ico-neprelaknabaziplastu.gif

And here is technical list:
http://www.motip.nl/upload/pdfuitzonderingen/TI/EN/000011%2012%2013.pdf

watson
31-01-08, 10:33 PM
I have no hesitation in saying I think this is one of the very best threads on this whole site, just outstanding, I am in awe.

misu
01-02-08, 01:24 PM
So, after more than two month of searching I've finally got all five parts of that big spoiler, what goes around a whole car... So it is time to try fit these parts, what unfortunatelly means drilling into body :cry: .
OK here are all five parts ready:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010021.jpg

Carefully measure, where to drill, is VERY important:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010022.JPG

Is that red cross, where it should be? Time will show...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010023.JPG

misu
01-02-08, 01:28 PM
As You can see, this spoiler covers also hole for radio aerial - another big hole, what I have to drill...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010024.JPG

Rear parts finished! Both sides are OK - right one...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010025.JPG

...and left one:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010026.JPG

Door parts fits perfect too:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010032.JPG

misu
01-02-08, 01:33 PM
Last, the biggest part - rear one!
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010029.JPG

As You can see, it fits OK again:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010031.JPG

Something from another barrel - center console finally mounted:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010028.JPG

And from another angle:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.01/P2010027.JPG

saabismi
01-02-08, 01:39 PM
Nice...Tho i thought ur gonna put aero bodykit on it:( ohwell looks good even with regular turbo ones:)

misu
01-02-08, 01:56 PM
Concerning Aero body kit - I am searching...

900chango
01-02-08, 02:49 PM
I just happened to see all of your work by accident. I am amazed!!!! at your dedication and skill. I saw a little of your album and I can't wait to see how it ends. Good luck the rest of the way.

misu
01-02-08, 03:59 PM
... I can't wait to see how it ends...
How? I will drive it, of course. No other way, when I spent so much money on it...:cheesy:

TooMany2cvs
18-02-08, 05:18 AM
Hey, Misu, you've gone quiet on it... Spring's coming along quickly - will the car be ready?

misu
18-02-08, 09:05 AM
Hey, Misu, you've gone quiet on it... Spring's coming along quickly - will the car be ready?
Well, it is more than two weeks from my last post here...
OK, today evening I will post some new pictures. Be ready!
Anyway, I am just preparing for its heart. I means clean the workshop, check those sophisticated tools (big and even bigger hammer), etc...
But You will see after couple of hours...

misu
18-02-08, 08:28 PM
New photos!

I've tried to mount front bumper, just to see, how it fits and test headlight wipers. So even without front grille car smiles again:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.14/p2140041.jpg

But I did something behind headlights. Bracket for intercooler is on place. Even it is not clearly seen (black part on black background), it is there. Intercooler will come later, I have to wash it, because it was full of oil - donor car had some turbo problem...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.14/P2140037.JPG

And for final, something from back side... I've stapled rear window section! It was quite easy, because I had an old one, so I've just followed existing staple holes on it (and stretch it a little bit, of course). Main top section is NIB, so it will be harder to stretch it correctly...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.14/P2140039.JPG

Those white spots are just dust particles, shinning in flash light.

misu
18-02-08, 09:24 PM
Because I will transport car into different location, where is hot enough for attaching conv. top, seats must be ready. So here they are, ready to be mounted. Their leather skins are covered with protecting foil.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.14/P2140034.jpg

http://www.zemekoni.org/files/Saab-900-Convertible/2008.02.14/P2140033.jpg

woywitka
19-02-08, 10:15 PM
Now I am stoked!


Think she will be ready for spring?

misu
20-02-08, 08:26 PM
Think she will be ready for spring?

I really don't know... I have to do whole engine and transmission. It means dismantle them into last screw, check, replace all worn parts, old bushings and seals, everything mount together, test and put into car... Lot of work, lot of money... Account is around 250.000,-CZK (10.000,-EUR) and counting...

James Bond
21-02-08, 12:41 AM
10k euros - not too bad for a baby for life! Just think, you could buy a Fiat Uno for that price!


If it helps, I paid GBP 8k for mine four years ago. Just had to have it!

Mine is very low kms and almost perfect condition, but nothing like yours which is perfection.

You will have years of pleasure from this project.

Did you find a new auto box?

TooMany2cvs
21-02-08, 02:29 AM
Lot of work, lot of money... Account is around 250.000,-CZK (10.000,-EUR) and counting...

Lot of work goes without saying, but that sounds bloody cheap to me so far.

misu
21-02-08, 06:44 PM
For all: I know, that this project costs lot of money, and i am ready to pay all bills, as they come. But sometimes I have to wait for a couple of days or weeks for another "financial injection"...:cheesy:

About automatic transmission. I have an old one, model 37 from 1987and as previous owner said - it should be perfect, but it stayed around two years inside garage, with open front cover... So what do you thing, should I rebuild it, or leave it and hope, that those two years of dust, entering into primary chain, did not "kill" any internal parts? What about lack of oil? What happens to internal O-rings, clutch plates, etc.?

I can borrow all special toolsand setting jigs, just for a bottle of good wine, so there is not a problem here.

James Bond
22-02-08, 06:07 AM
For all: I know, that this project costs lot of money, and i am ready to pay all bills, as they come. But sometimes I have to wait for a couple of days or weeks for another "financial injection"...:cheesy:

About automatic transmission. I have an old one, model 37 from 1987and as previous owner said - it should be perfect, but it stayed around two years inside garage, with open front cover... So what do you thing, should I rebuild it, or leave it and hope, that those two years of dust, entering into primary chain, did not "kill" any internal parts? What about lack of oil? What happens to internal O-rings, clutch plates, etc.?

I can borrow all special toolsand setting jigs, just for a bottle of good wine, so there is not a problem here.


Personally, I would check everything in the auto box (if I knew how to!).

What power will your engine have? Mine is supposd to be about 220 bhp with the Abbot modifications, and I hear that the auto box will not take more than 200 bhp.

I drive mine like a grandad (most of the time!) and am always thinking about when it will change up to 3rd and if it is ok! Saab psychosis!

woywitka
25-02-08, 01:44 AM
Even if it is rebuilt it will never be the same, the automatics don't rebuild well.


THe automatic will make the car feel very dated and give a poor ride IMHO. I just have not been impressed with the automatic, it is a VERY dated deisgn that pulls enjoyment away.

It is with complete honesty that I suggest you consider a Manual Gearbox. See if you can at least try a 900 with a MT. The clutch action is very nice, and with a light rebuild they are still enjoyable transmissions.

With your skills you could rebuild a nice 5-speed for little money. Some new pinion bearings, a reverse idler, a syncro or two, and perhaps a selector fork and your laughing.

misu
26-02-08, 02:27 PM
Even if it is rebuilt it will never be the same, the automatics don't rebuild well.


THe automatic will make the car feel very dated and give a poor ride IMHO. I just have not been impressed with the automatic, it is a VERY dated deisgn that pulls enjoyment away.

It is with complete honesty that I suggest you consider a Manual Gearbox. See if you can at least try a 900 with a MT. The clutch action is very nice, and with a light rebuild they are still enjoyable transmissions.

With your skills you could rebuild a nice 5-speed for little money. Some new pinion bearings, a reverse idler, a syncro or two, and perhaps a selector fork and your laughing.

I know all You wrote and maybe at the future I will change it back to manual, but for this moment I will try automatic.

James Bond
27-02-08, 12:42 AM
It is not so bad, the auto.

The power comes in at just the right place.

Best for calm steady cruising, or around the city.

jameschong
27-02-08, 04:27 AM
I find that the auto allows boost to be maintained when changing gears.

eXunforgiven
10-03-08, 02:29 PM
Wow that is an insane restoration, Good job. Still quite a bit to go huh? Good luck with the rest.

misu
10-03-08, 09:42 PM
So, something new from my garage:

You saw front bumper on place. Now it went out again, because I had to mount an oil cooler. Here you can see hanging it on its new hoses...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.07/P3070004.JPG

... and here is finally mounted:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.07/P3070006.JPG

From a second angle:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.07/P3070005.JPG

Cooler itself is new, its bracket is sand blasted, zinc coated and then powder coated. Screws and nuts are zinc sprayed (they are new, as all others).

As you can see at previous photo, there is an intercooler on its place. So a view from opposite side shows not just intercooler, but water cooler too, with its fans. Both fans are restored, it means dismantled (very hard to loose rusted nuts on their axles, but I did it - force won), cleaned, greased and tested.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.07/P3070002.JPG

woywitka
10-03-08, 09:55 PM
wow, gets me so excited!:D

misu
10-03-08, 10:03 PM
Well, convertible, it is a soft top, too...

You saw, that a rear part, together with a rear window, is already mounted. So now is time to mount the reast - main top section. Front edge was quite easy, I've just followed service manual step by step:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.07/P3070008.JPG

Next section was flaps around rear quarterlights. It was even easier...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.07/P3070009.JPG

So only those rear edges are parts to do. Actually, I've done them yesterday, but photos will be ready tomorow, or next day after...
All I can say is that to fit this top was very easy, straightforward, one of the easiest work on the car. I am just affraid, that I missed something very important, but I really do not know, what... So, future will show...

TooMany2cvs
11-03-08, 03:30 AM
... and here is finally mounted:
http://www.saabphotos.com/gallery/albums/album766/P3070006.sized.jpg

This photo really sums up your project for me, Misu.

You've done all that work, got everything back to perfect finish - but you're not afraid to cover it all with protective spray so it STAYS good, even if it doesn't look "Ooh-it's-too-nice-to-use" pretty. Because you're going to USE the car.

Good for you.

VikingSpirit
11-03-08, 04:21 PM
out of interest what is the protective spray that you hve used misu? I can see you have used copper grease in some areas, but whats silver stuff?

misu
11-03-08, 07:09 PM
out of interest what is the protective spray that you hve used misu? I can see you have used copper grease in some areas, but whats silver stuff?
It is zinc pray, specially designed for protecting screws and nuts... A gift from my friend. Fact is, that this one and cooper spray (not grease) I've used on another areas, are the same. But zinc one I have in garage, cooper one I have in workshop...

misu
24-03-08, 10:02 AM
Hi,

after a couple of days of silence, I am back with some more photos. So, soft top is finished, together with side spoilers:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.23/P3230003.JPG

Also all four windows are mounted and aligned (door spoiler has a different colour from side one, but it is just on this photo, maybe because of flash light...):
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.23/P3230005.JPG

There is something new inside an engine bay - air cleaner pot...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.23/P3230007.JPG

...and hydraulic hoses from power steering.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.23/P3230006.JPG

misu
24-03-08, 10:10 AM
But what is really big change, it is a HOOD!!! Yes, I have hood finished and now you can see, how it looks - from right side:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.23/P3230002.JPG

And from left side:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.23/P3230001.JPG

I've received a new (used) ABS control module, so now ABS works (control light says that) and I can finish interior. First step was to cover holes for lift mechanisms of quarterlights and moisture protection inside doors:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.23/P3230008.JPG

I had a red foil only...
Next step here - upholstery and seats. Next step inside engine bay - engine and transmission. Actually, transmission is first at queue...

saabjunky
24-03-08, 07:45 PM
Did you buy a new top? And if so, what company did you use for the purchase? It sounds like it was a pretty easy install, was that actualy the case?


Thanks in advance

misu
25-03-08, 10:28 AM
Did you buy a new top? And if so, what company did you use for the purchase? It sounds like it was a pretty easy install, was that actualy the case?


Thanks in advance

Yes, I bought a new top and headliner, rear window I bought slightly used on eBay. Actually, I bought top on eBay too, but as a new stuff, from some german company, Cabrio-verdeck (IIRC)...
And finally yes, installation was like a piece of cake, I've just followed service manual step by step. And I can say, it was one of the easiest work on the car.

misu
31-03-08, 07:46 PM
Well, upholstery already finished. Now it looks more comfortable than last year at this time...
During instalation...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.27/P3270003.JPG

...and after.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.28/P3280020.JPG

Opposite side:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.28/P3280019.JPG

jameschong
31-03-08, 08:33 PM
Coming along most nicely! I must say this is my most anticipated thread on the forum to-date. It's like waiting for a birth!!!

misu
01-04-08, 10:10 PM
Transmission rebuilt started!

I've bought this transmission from one of independent Czech Saab service. They said that this tranny is in perfect condition, just cleaning and fresh ATF, that is all, what it needs.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.27/P3270005.JPG

Anyway, I've decided to open it. Fortunatelly. Look, what was inside:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.27/P3270010.JPG

Oil filter and one of overflow tubes were damaged. Filter will be new, tube was easy repaired. But there were another "surprise" under next cover. Look carefully, those small metal "pellets" between metal pipes:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.27/P3270009.JPG

It was an axial needle bearing between front and rear clutches. Here is its cage:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.31/P3310042.JPG

misu
01-04-08, 10:24 PM
Look here. I am just opening 1-2 accumulator:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.29/P3290002.JPG

And another "surprise"! This is its spring:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.03.29/P3290005.JPG

Third broken part are dish springs, what hold front clutch piston in its rest position. They are broken on many pieces. Photo will follow soon.
And dismantling of transmission is not finished yet. So, maybe some another "surprises" are waiting for me...:cry:

woywitka
02-04-08, 12:58 AM
uh oh......


Looking great, hope the rebuild goes well.

I'm crusin in a 91 turbo Automatic right now with a BW type 37 in really good shape, much nicer than my type 35 expereince. The thing is fairly smooth with no vibration at idle whatsoever.

misu
06-04-08, 09:50 PM
So, dismantling of transmission is nearly finished. Case is almost free from all moving parts, just pinion with its mounting bracket is waiting. Rest of parts looks well, I am not sure about spring inside governor, but I had no time to open it yet. Also do not know anything about springs inside "brain" - valve body and about oil pump.

Some photos are at saabphotos, as usually, they are many, so I decided not to copy all of them here, but for your interest here you are empty case (it will be cleaned, of course):
http://www.zemekoni.org/files/Saab-900-Convertible/2008.04.06/P4060021.JPG

Another view:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.04.06/P4060023.JPG

And here are some big and heavy parts from inside:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.04.06/P4060026.JPG

Small parts are here:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.04.06/P4060027.JPG

Each part has label with part number from EPC, so rebuild will be easy (I hope).
Loved czech customs sent me a note, that some shipment came to me from USA and Czech State decided to take some more money from my pocket, so I have to go to them and pay taxes. It is bad thing. Good one is, that it is shipment from saabsite with a transmission master rebuilt kit. Tomorow I will tell you more, and send some photos of this kit.

James Bond
07-04-08, 02:07 AM
You can still get a rebuild kit for these auto transmissions?

From where?, please? :)

Matthew
07-04-08, 05:14 AM
I have always thought that the most bonkers DIY job on a 900 would be an automatic gearbox rebuild. The EPC diagrams look terrifying :lol: In seven years' membership of this forum I've never even heard of anyone attempting it.

Well done! :D

Great photos of the rebuild - can't wait to hear more on this story.

You're fortunate to be building up the car under cover. When I do mine, it'll all be outside :cry:

misu
07-04-08, 06:10 PM
You can still get a rebuild kit for these auto transmissions?

From where?, please? :)

Yes, I can. And do You want an address? OK, here is: www.thesaabsite.com (http://www.thesaabsite.com)
Kit came today and it is really perfect. Every seal, every O-rings, all wearable parts together with clutch plates, in signed bags, plus both brake bands in one box.

misu
07-04-08, 06:18 PM
I have always thought that the most bonkers DIY job on a 900 would be an automatic gearbox rebuild. The EPC diagrams look terrifying :lol: In seven years' membership of this forum I've never even heard of anyone attempting it.
Dismantling was easy, I've just followed a service manual... Question is, how it will back together and how it will work... But at the factory, they built these trannies every day in hurry... So it cannot be so hard to rebuilt, I hope...

Well done! :D

Great photos of the rebuild - can't wait to hear more on this story.

Thank You.


You're fortunate to be building up the car under cover. When I do mine, it'll all be outside :cry:

I couldn't do this project without garage and workshop. It is too complicated and too complex to be done outside. But if You would live here in Czech during socialistic era, you would learn a much...

James Bond
08-04-08, 02:41 AM
Yes, I can. And do You want an address? OK, here is: www.thesaabsite.com (http://www.thesaabsite.com/)
Kit came today and it is really perfect. Every seal, every O-rings, all wearable parts together with clutch plates, in signed bags, plus both brake bands in one box.

Thanks.

Good to know that the parts are still available.

misu
09-04-08, 10:55 PM
Tranny rebuilt problem!

Actually I have four real problems... First one is broken thrust bearing. Its dimmensions shows to 1625 size and it looks very similar to Torrington NTA-1625 but I have rpoblem to buy it and let it ship into Czech Republic... It is 1 inch int. diam. (FYI)... Also its washers are worn, so only one possibility is to resurface them, because they are custom built. Maybe I could put standard, metric bearing with metric washer in one side and second washer resurface. But this washer has a smaller outside diameter, then bearing itself. Is it a big issue, when a small part of needles will rotate "in air"?

Second problem is broken spring. I do not know its strength, so I cannot let make a new one. But I have an idea - to put a pin inside this spring, shorten then this spring in fully pushed state, so the spring can work, even it is broken, its strength has changed, but just a little bit...

Third one are those dish spring and last one is pinion nut - it has a non standard dimmension, 43 mm. Commercially avaiable sizes are 41 and 46 mm... Buy 41 and grind it?

James Bond
10-04-08, 02:19 AM
Misu,

You might get more replies if you post this in the general C900 section and on Saabnet!

Sorry I can't help.

Peter

misu
10-04-08, 08:18 PM
You culd be right, but as Matthew said a couple of posts before, I am one of the very few, who is trying to rebuild automatic transmission for classic 900, so it will not be so hot with replies...

Anyway, today afternoon I will go for another auto tranny, what should be OK. It would be really under Murphy laws, when this one would have the same problems, the same broken thrust bearing (what is the biggest issue, I think)...

James Bond
11-04-08, 02:30 AM
So you have Murphy in Czecko too!

He's a friend of mine, I see him often!

TooMany2cvs
19-04-08, 11:37 AM
Hey, Misu... How's it going? Still autobox problems, or have things moved ahead?

misu
20-04-08, 05:47 AM
Hey, Misu... How's it going? Still autobox problems, or have things moved ahead?

Hi,
many things changed!
First of all, I bought another tranny, what should be in much better state. When I tried to bring it home, my daily car decided to go over... Fortunatelly just front of my home. So I bought another Saab, now it is 9-5 in dark blue with beige interior, wood, automat, 2.3T, chipped.

And tranny was fine, except differential. Because lack of oil inside, one of ball bearings on pinion shaft broke. Not necessary to describe, what they done to teeth of pinion a nd crown wheel... But front part of transmission, its heart, is perfect.

So, I've decided to use its case and its internal parts, except differential, actually except pinion bearing housing, pinion and crown wheel. Rest of differential unit looks better, then first one. I will change all bearings inside this area, it means twoo ball bearings for output shafts, two tappered bearings for differential and both bearings for pinion shaft, of course.

Now I have a cleaned case, covers and almost all internal parts, except valve body and hydraulic pump, removed bearings from differential and still need to dismantle old pinion shaft (from the first tranny) and remove both crown wheels (those twelve bolts with locking fluid)...
Tomorow I will buy a new bearings and a fresh oil and can start to assembly it. if everythiong will go fine, at the end of next week tranny will be ready to be put under engine (what is not ready yet...).

woywitka
21-04-08, 06:09 AM
Hi,
So I bought another Saab, now it is 9-5 in dark blue with beige interior, wood, automat, 2.3T, chipped.





whoa whoa whoa, hang on there!


pictures, please!

misu
21-04-08, 04:03 PM
whoa whoa whoa, hang on there!


pictures, please!

I will take pictures as soon as rain will gone (one week clouds and rain. Is this that global warming?)

misu
04-05-08, 07:20 PM
So, after a couple of weeks of silence, new photos are ready. So watch and enjoy an old Borg-Warner rebuild...

New bearings for differential pinion - Timken, as original. You can see an old inner race at left side...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020006.JPG

All tappered bearings are Timken, all ball bearings are SKF, here are one for oil pump and one for input shaft.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020008.JPG

Let's mount oil pump now... A new bearing is already on shaft. There is fresh a transmission fluid inside that plastic cup. Quite hard to buy, because this transmission needs very special fluid, only Shell supplies a right one, and in 20 litres barrels only... Fortunatelly, I could buy it from Slovak company in 1 liter bottles.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020009.JPG

Time for open a magic box - big rebuilt kit with all necessary O-rings, seals, clutch plates and bands.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020010.JPG

misu
04-05-08, 07:34 PM
Let choose a right one seal and install it into pump case...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020011.JPG
Next step is mounting everything together again. Do You see a small scratch on pump gear teeth? I've made it during dismantling to set everything exactly as it was before...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020013.JPG

When tightening, a right tool - torque wrench, is essential.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020014.JPG

Pump finished and packed in wrap foil until final assembly.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020015.JPG

Next step is pinion bearing housing...

misu
04-05-08, 07:49 PM
Ok, here are some parts - housing and two seals, ready to be install. One seal closes differential chamber, a second one closes gear changing mechanism itself. betwwen them is a free space, with ventilation hole. This hole must be free from any dirt - eventual leak of one or second oil can escape thru this hole.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020017.JPG

Both seals are correctly installed, now put outer bearing race for rear pinion bearing.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020018.JPG

Rear and front outer races are installed, time to put pinion in.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020019.JPG

And that's all for this moment, because I have to wait for a special tool (torque wrench for small torques) to arrive, so let's put it aside and work on another sub assembly.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020020.JPG

misu
04-05-08, 08:00 PM
This assembly is governor. Rebuilt kit contains also steel sealing rings, so let's change them. Old ones are thore in right, new ones are above.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020021.JPG

Finished governor needs to be mounted on toothed wheel - those outside teeth are for parking pawl... Governor is held by one screw only.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020023.JPG

Governor subassembly finished. Now wrap it into foil and put aside for final assembly. Next step: rear clutch.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020024.JPG

misu
04-05-08, 08:17 PM
And here it is. So, first of all change steel sealing rings. Old ones are above, new ones are on right.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020025.JPG

Here You can see all almost parts for rear clutch (steel friction plates are outside of picture). Inner friction plates are soaked inside transmission fluid, inside bag are new seals for piston (together with seals for front clutch piston, too), piston itself, its return spring and lock ring. Mount that piston, compress that big spring was a quite hard, but nothing bad happened and we can go further...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020026.JPG

...and put all friction plates, inner and outer, in correct order. Because steel ones are dished, you must note even its correct side position.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.03/P5030027.JPG

So, rear clutch is finished, put it aside and work on front one.

misu
04-05-08, 08:29 PM
New seals are ready. You can see old ones, labeled, on left side. And as You can see those two seals are last on this bag. Borg-Warner for classic 900 has no any third clutch...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.03/P5030029.JPG

Piston is instaled, together with its dish springs. Now let's put friction plates...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.03/p5030030.jpg

All plates are ready, together with inner hub and thrust washer. Input shaft will be instaled, but first I have to change its old steel seals.
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.03/P5030032.JPG

New ones on its bag, old ones on shaft...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.03/P5030033.JPG

And thats all for today, because I forgot to photo finished clutch with input shaft. But as usually, I've put it aside to wait for final assembly.
Next step is differential. And one sensor inside engine oil pan. As you remember (maybe), I've decided install gauges from 9000, with oil level check, so this feature needs some input...

James Bond
05-05-08, 02:04 AM
Wonderful!

Matthew
05-05-08, 07:05 AM
It's a pleasure to see the progress of this project.

Where did you learn to rebuild automatic gearboxes?

misu
05-05-08, 08:41 AM
It's a pleasure to see the progress of this project.

Where did you learn to rebuild automatic gearboxes?

During this project...:cheesy:

I have some technical skills, of course, but this is my first auto tranny I am trying to rebuild. In fact, when carefully studied service manual, understood its function, how it exactly works and if You follow manual step by step, there is a good chance to rebuild it fine.
And my friend, who is owner of small Saab service, help me a lot...

Will see, how good I am, at the future, when I wil try to drive this car...

misu
13-05-08, 01:16 PM
Hi guys, show continues!!!

Last time I've spoke about oil level sensor inside oil pan... So here it is:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020001.JPG

Sensor itself is from 9000, but is mounted from inside. Wires are free of any isolation, I was afraid about degradation of its material inside a hot oil...
Here you can see "terminals" of those wires... I will solder ordinary cables here and cover everything with hot glue or something similar...
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020002.JPG

Well, oil pan is done, now differential. As I said already, I've put all new bearings, and it means that I have to set up their preload. But my knowledge of english are not so good to describe this process, so just watch pictures (if you like it). Left cover with bearing support:
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020003.JPG

Right cover. As you can see, screws are new (as usually)
http://www.zemekoni.org/files/Saab-900-Convertible/2008.05.02/P5020005.JPG