Aussiebob's Aero [Archive] - SaabCentral Forums

: Aussiebob's Aero


Aussiebob
16-02-07, 02:52 AM
My 1988 Aero Turbo is a lifelong (long life) dream and because of SAAB Central and other forums I have been inspired and informed to undertake a program to get rid of Go! and replace with GO!!!!!
Car at present nothing out of the ordinary but want to get to extraordinary

Plans include:

Relocate Battery (complete)
Fit front mount intercooler - have i/c ready to start fitting
Rebuild dump pipe to allow for greater exhaust flow, 2.5" all the way - underway
Fit better air intake - underway
Rebuild and fit modded APC - APC mod complete waiting on other bits before fitting
Fit adjustable FPR - have unit yet to fit
Fit new guages into spare DIN slot, either digital maybe analog - thinking
Fit 4 speed manual box - have box ready for rebuild and fitting - later!
Will add threads as the project evolves

http://i140.photobucket.com/albums/r12/austmanbob/101_0120.jpg
http://i140.photobucket.com/albums/r12/austmanbob/101_0121.jpg

Aussiebob
16-02-07, 03:22 AM
This has been posted elsewhere but repeated to keep the project together.

I relocated the battery into the back and this has been successful with no issues but if I was to do this again I would seriously consider the mod that was done by IronJoe on Blue Beast - mounted in the engine bay, left hand side. Less work, less cable, less cost.

http://i140.photobucket.com/albums/r12/austmanbob/900T_Battery/101_0122.jpg

http://i140.photobucket.com/albums/r12/austmanbob/900T_Battery/101_0123.jpg

http://i140.photobucket.com/albums/r12/austmanbob/900T_Battery/101_0124.jpg

http://i140.photobucket.com/albums/r12/austmanbob/900T_Battery/101_0125.jpg

http://i140.photobucket.com/albums/r12/austmanbob/900T_Battery/101_0127.jpg

Murray
16-02-07, 03:46 AM
You have done a nice tidy job with that battery, very purdy, how did you manage to colour match the carpet!?

I have seen it done where people have cut through the false floor on the boot and tucked it into the corner with some carpet over it!

I am considering doing this but i dont know how i want to go about it yet, i will look into moving it to the other side of the engine bay first i think! Looks good though!

Have you got any pictures of the whole car!???

sab aero
16-02-07, 04:04 AM
Nice job on the battery re-location.

I have a 1988 900 Aero too.... highly modded! :) Good to see another Aussie with the classic passion.

I found I didn't have to move my battery at all tho... i'm running a split 3" downpipe and it has just enough clearance.

You can read about all my upgrades I've done over the last 10 years of ownership of the silver sled at my site: http://www.saabclub.org.au/sbsaabonline/900_aero.htm I have taken it about as far as I want and I'm guessing she is putting out about 200kW or so. Lotsa fun to drive! My recent purchase tho is a 2002 9-3 Aero that I plan on getting around 240kW out of. Pics of that on my site too. I still have the classic and would never sell it!


If you want any tips from a fellow Aussie Saaber, just PM me and I would be glad to help.

Are you in the QLD branch of the club?

cheers from Melbourne
Steve (aka sab)

Aussiebob
16-02-07, 04:04 AM
The box is made from ply and carpet from a rear seat back from a donor car. Very strong and insulated. reasonably easy install.

Aussiebob
16-02-07, 05:09 AM
Have purchased this intercooler after much agony over type, size, new or secondhand. Looked at 9000 and Volvo but everyone said they were too restrictive. This one cost A$149 delivered which is the same approx as a secondhand 900 / Volvo. There are lots of suppliers on "you know what" in the US and Australia
It is 450mm x 300mm x 75mm of core with an overall length of 630mm - in and out are 2.5". It fits superbly between the headlights and suits a standard Aero bar and spoiler.

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/101_0132.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/101_0135_2.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/101_0137_2.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/FrontToothless_3.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/Trial_2.jpg

Will add further photos as the project goes on.

Aussiebob
16-02-07, 05:20 AM
Hi Sab
Read the article. Dyno ran my stock unit locally and got 115kw at the wheels, only mod was a bigger exhaust, so not too shabby. Using this as a benchmark for the mods.
Not yet a member od SCCA - have been emailing David Newman from the Qld branch and will join. They have some events coming up soon.

Aussiebob
18-02-07, 02:20 AM
Fitted up the intercooler up to trial fit and I am impressed the way it fits. Acouple of 8mm bolts and a little alloy tube for dress will hold the top. I have about 1.5mm between the cooler and the bar (retaining the air cond condensor) and with the towing hooks demise I have a reasonably clear run into the engine bay. If the rain would only stop I could get on with it - funny drought this!!


http://i140.photobucket.com/albums/r12/austmanbob/FMIC/Front_fit_2.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/TowHooksGone_2.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/BarOn_2.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/UnderFit_2.jpg

Looking at "ventilating" the bar. There has been reference to somone doing a job on the bar to increase flow - anyone have a link??

Squaab99t
18-02-07, 02:41 AM
Looking at "ventilating" the bar. There has been reference to somone doing a job on the bar to increase flow - anyone have a link??

Bar= Bumper? well then yes.
http://www.saabphotos.com/gallery/album481
last page has some pixs of the venting process. The center section foam is cutout and the euro plate plastic location is removed. You may run into a problem of the licence plate location.
http://www.saabphotos.com/gallery/albums/album481/CIMG5461.sized.jpg

Matthew
18-02-07, 05:49 AM
Bob, that's the best battery relocation job I have yet seen. Love the attention to detail :cool:

eddiethegreat
18-02-07, 06:04 AM
Bob, that's the best battery relocation job I have yet seen. Love the attention to detail :cool:
I agree.
You had a great idea. I've always asked myself where to fit the 100Ah battery of my parents' caravan. I'll get your copyright :lol:

ShadowWorks
18-02-07, 09:43 PM
I think Bob is a carpenter;)

Aussiebob
19-02-07, 02:22 AM
I think Bob is a business consultant working for the Government. He is also a PITA sometimes having to get everything "just right"

cinemarr
24-02-07, 09:09 AM
Nice job on the battery re-location.

I have a 1988 900 Aero too.... highly modded! :) Good to see another Aussie with the classic passion.

I found I didn't have to move my battery at all tho... i'm running a split 3" downpipe and it has just enough clearance.

You can read about all my upgrades I've done over the last 10 years of ownership of the silver sled at my site: http://www.saabclub.org.au/sbsaabonline/900_aero.htm I have taken it about as far as I want and I'm guessing she is putting out about 200kW or so. Lotsa fun to drive! My recent purchase tho is a 2002 9-3 Aero that I plan on getting around 240kW out of. Pics of that on my site too. I still have the classic and would never sell it!


If you want any tips from a fellow Aussie Saaber, just PM me and I would be glad to help.

Are you in the QLD branch of the club?

cheers from Melbourne
Steve (aka sab)

That Silver SLed is a beauty!

beegee
17-03-07, 07:26 AM
Have you got any futher with the intercooler?

Sorry but I am just being lazy and seeing how well yours goes before doing mine;) :cheesy:

Aussiebob
19-03-07, 07:18 AM
My appologies - I have been sidetracked working on my 99EMS - putting in 5 speed inlieu of the 4 speed to get better highway performance.

I have fitted the intercooler and have clocked the turbine so the outlet faces forward and down. This helps with a smooth piping arrangement through to the FMIC inlet. Having a little challenge with the turbo oil return because of the clocking. I have made up a fitting for the block and threaded the origional oil return hole 1.125 NPT-14 - perfect fit. I now have a hosetail in the bock. Have to make up a new pipe off the turbo. Will post photos soon but attached is the fitting I made for the block.


http://s140.photobucket.com/albums/r12/austmanbob/FMIC/th_Parts2001.jpg

ShadowWorks
03-04-07, 03:34 AM
Any pictures of this clocked turbo Bob?

Sounds interesting, I attempted to clock my turbo but gave up in 3 seconds when I realised I didn't have anything to make new pipes with.

Aussiebob
09-04-07, 06:07 PM
This project is getting like "War and Peace" (a really long book - for the younger members).

It is getting close but I keep changing my mind - 3 steps forward 2 back all the time.

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/OilReturn.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/ClockedTurbo.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/MandrelBentICPipe.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/ICBracket.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/InstallPipe.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/AirIntake1.jpg

Aussiebob
09-04-07, 06:18 PM
Bar= Bumper? well then yes.
http://www.saabphotos.com/gallery/album481
last page has some pixs of the venting process. The center section foam is cutout and the euro plate plastic location is removed. You may run into a problem of the licence plate location.



Will get to my "Bumper Bar" soon.
Looking at doing my exhaust next - apart fron the O2 sensor what other possible fittings should I allow for in the new top pipe.
Also on the air intake pipe from the I/C to the inlet manifold what should I allow for in fittings. I see you have a blow off valve mounted - what else? - Pressure gauge?

Squaab99t
10-04-07, 01:55 AM
Will get to my "Bumper Bar" soon.
Looking at doing my exhaust next - apart fron the O2 sensor what other possible fittings should I allow for in the new top pipe.
Also on the air intake pipe from the I/C to the inlet manifold what should I allow for in fittings. I see you have a blow off valve mounted - what else? - Pressure gauge?

Exhaust: Are you sticking w/ the internal WG? I switched to an external. I bought mine locally, but IronJoe made his own. I'd add 2 O2 bungs. When I dynoed I left mine in and compared w/ the dyno's reading at almost the same location. I'm going to drill and tap a plug and add a pyrometer sensor.

Intake: I have bungs for an air temp sensor, and 2 H2O nozzles. pressure I get off the manifold. You want that pass the T/B. A tip from a tuner; He said the Blowoff valve bung would be better if it were perpendicular to the straight section of tube. Right now mine is in the elbow.

Aussiebob
10-04-07, 04:09 AM
Exhaust: Are you sticking w/ the internal WG? I switched to an external. I bought mine locally, but IronJoe made his own. I'd add 2 O2 bungs. When I dynoed I left mine in and compared w/ the dyno's reading at almost the same location. I'm going to drill and tap a plug and add a pyrometer sensor.

Intake: I have bungs for an air temp sensor, and 2 H2O nozzles. pressure I get off the manifold. You want that pass the T/B. A tip from a tuner; He said the Blowoff valve bung would be better if it were perpendicular to the straight section of tube. Right now mine is in the elbow.

Thanks for your comments. At present I am sticking with the internal wastegate but which one do you use. Other comments noted and appreciated.

Aussiebob
10-04-07, 04:46 AM
Exhaust: Are you sticking w/ the internal WG? I switched to an external. I bought mine locally, but IronJoe made his own. I'd add 2 O2 bungs. When I dynoed I left mine in and compared w/ the dyno's reading at almost the same location. I'm going to drill and tap a plug and add a pyrometer sensor.

Intake: I have bungs for an air temp sensor, and 2 H2O nozzles. pressure I get off the manifold. You want that pass the T/B. A tip from a tuner; He said the Blowoff valve bung would be better if it were perpendicular to the straight section of tube. Right now mine is in the elbow.

Can the pressure be taken from the pipe

Squaab99t
10-04-07, 10:26 AM
Thanks for your comments. At present I am sticking with the internal wastegate but which one do you use. Other comments noted and appreciated.

I used the Tial sport. My fav are the Turbosmart from your area, but the Tial came with the downpipe and is made in the USA. Both are pretty good units.

Squaab99t
10-04-07, 10:27 AM
Can the pressure be taken from the pipe

I took mine from the manifold because that is what the engine sees thus my ecu sees the same vacuum/pressure.

IronJoe
10-04-07, 10:34 AM
I used the Tial sport. My fav are the Turbosmart from your area, but the Tial came with the downpipe and is made in the USA. Both are pretty good units.

+1 I've had nothing but good experiences from my tial as well. I love the interchangeable springs, much better than cranking an actuator rod!

Aussiebob
07-05-07, 05:36 AM
Taken more time than I wanted but the FMIC job is now done.

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/Bracket.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/FrontNearly.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/FrontFin.jpg

Now onto the exhaust dump. After which I will put it on the dyno and see how much difference it all has made. Thinking of running with and without the exhaust mod to see if teh SAAB cast elbow is as bad as we all think. Will then do the other fuel mods.

James Bond
07-05-07, 06:38 AM
Hello Folks,

Do I understand well? It is possible to fit an external wasetgate?

I'd like to do this, (mine is seized, and keeps on seizing) by leaving the exisiting valve on the turbo in place and fitting a valve elsewhere.

How do I do this?

TIA.

Aussiebob
04-07-07, 08:40 AM
Well I have fitted the front mount intercooler, improved the air intake, fitted new dump pipe to rid myself of the cast elbow and fitted an adjustable fuel pressure regulator. Lost the boost and pathetic spool up - no accelleration.

A set of new guages - Boost, Fuel/Air ratio and engine water temp. Fuel/Air shows very lean condition. Fitted new oxygen sensor - no improvement. Lifted fuel pressure to 3 bar with standard injectors. Had injectors cleaned and tested.

Why would the O2 sensor and therefore Fuel/Air guage show very lean. Do I have a very lean condition??? How do I rectify????

Albert Trout
04-07-07, 08:59 AM
Are you on bog standard Bosch injectors Bob? When you say lean what's the actual AFR? What boost you running

The stock injectors with the Bosch ECU don't flow a huge amount of fuel but I don't think you should be leaning out yet. Turn the FPR up higher as well. At least 3.3 bar. A guy local to me has a modded 900 with Bosch and he runs 3.7 bar on the FPR. I run 3.3 bar but the Lucas injectors are bigger.

Squaab99t
04-07-07, 11:23 AM
Hello Folks,

Do I understand well? It is possible to fit an external wasetgate?

I'd like to do this, (mine is seized, and keeps on seizing) by leaving the exisiting valve on the turbo in place and fitting a valve elsewhere.

How do I do this?

TIA.
It is possible, but a bit more involved. You must remove the swingate housing and diaphram actuator and replace it with a different setup.
http://www.saabphotos.com/gallery/albums/900T-Downpipe-and-Exhuast/CIMG3023.sized.jpg
http://www.saabphotos.com/gallery/albums/900T-Downpipe-and-Exhuast/CIMG3024.sized.jpg

Squaab99t
04-07-07, 11:28 AM
Taken more time than I wanted but the FMIC job is now done.

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/Bracket.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/FrontNearly.jpg

http://i140.photobucket.com/albums/r12/austmanbob/FMIC/FrontFin.jpg

Now onto the exhaust dump. After which I will put it on the dyno and see how much difference it all has made. Thinking of running with and without the exhaust mod to see if teh SAAB cast elbow is as bad as we all think. Will then do the other fuel mods.

Nice job on the bumper grill insert. What did you use for material and did you glue it in from the back side? Mine is still a gaping large mouth bass of a fish.

Aussiebob
04-07-07, 06:16 PM
Nice job on the bumper grill insert. What did you use for material and did you glue it in from the back side? Mine is still a gaping large mouth bass of a fish.

I found a plastic rack from a freezer and cut to suit. Glued it in from the inside. Not quite satisfied with the job but will perfect later. Found the rack at the the local "dump shop". Dont know if you have these but our council runs the local refuse station (garbage dump) and they have a shop there selling stuff people have thrown away. My son picked up a Recaro racing seat, had it recovered and now it is like new.

Aussiebob
12-07-07, 06:50 PM
http://s140.photobucket.com/albums/r12/austmanbob/th_DumpPipe.jpg2.5" mandrel bent dump pipe. I will clean up and maybe wrap to keep the heat out of the engine bay. Extra O2 sensor space for dyno testing.

http://i140.photobucket.com/albums/r12/austmanbob/DumpPipe.jpg

IronJoe
12-07-07, 07:05 PM
Well done Aussiebob! Looks like a nice wide bend. Drive it yet?


Also, any way to get that IC pipe further away from the downpipe? I know it's before the intercooler but still, every bit helps and the downpipe gets incredibly hot.

Aussiebob
13-07-07, 03:47 AM
Well done Aussiebob! Looks like a nice wide bend. Drive it yet?


Also, any way to get that IC pipe further away from the downpipe? I know it's before the intercooler but still, every bit helps and the downpipe gets incredibly hot.

Thanks Joe - Have driven but in another thread I described an issue I have with leaning out since the FMIC, air intake, adjustable fuel pressure reg, and dump. Looking into the proble at the weekend. Once problem solved I want to dyno test it to see the overall difference from stock.

88-16Tconv
31-07-07, 01:48 AM
Bob,

Where did you run the ground on the battery to?

Thanks