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  #1  
Old 18th July 2018
300sdl's Avatar
300sdl 300sdl is offline
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Default Fixing the rusties

Hi everyone. Recently acquired a 9-5 Wagon 2003, 185k miles. Northern car....
My first Saab! Well he's all rusted and rotted in the typical areas. Wheel arches, rocker panel, wheel well... Having performed these types of repairs before I figured I would share my methods and periodically update the progress with pictures and post about the work performed and answer questions. Hopefully have an open forum. The last restoration I did took 6 months of work which took place over 7 days a week averaging 8 hours per day. I would take photos everyday and write a post and share the pictures. I organized everything in folders on a Google drive and named each folder with date and description. A link will be below for those interested in prior restoration (non saab).


Anyways as for today here are some photos.

https://drive.google.com/folderview?...UgtdTyMVhjUZDg

Last restoration

https://drive.google.com/folderview?...XhLclY4eGVXMEk

These pictures are on another forum for those interested.

Random pictures of Saab.

https://drive.google.com/folderview?...KiVmR0vOOFpWRN
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  #2  
Old 19th July 2018
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300sdl 300sdl is offline
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Well here is today's update. I had to order a new oxy acetylene torch handle because my purox unit doesn't have a tip small enough for this sheet metal. Well I ordered a 100fc victor because I had the correct tips. Ordered a couple days ago got it today (see pic). I also had to order a metal shaping bag and teardrop mallet. Those came in today as well, so I formed one of the clearance dimples for the rear strut (see pic). I'm still a while away from welding. I prefer to remove as much material as possible, clean everything, coat in weld primer, fabricate and then assemble. Sometimes I do weld as I go but usually save it for last. Prep is important!
https://drive.google.com/folderview?...7xFzeO441Lu1tk
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  #3  
Old 19th September 2018
crxb5 crxb5 is offline
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not to kill your vibe... but you are spending a lot of your time making repairs on cars which are not worth it.


According to your post you spent 56 hours a week for 23 weeks which is roughly 1200 hours of your labor. I charger $65 dollars of labor for repairs I do for customers. So I would be charging someone $78,000 to do what you did (for the dodge)... not saying it would take me that long just trying to put this into prospective. The van is not even worth 3k unfortunately... AAllocate your time wisely...
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  #4  
Old 19th September 2018
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300sdl 300sdl is offline
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Quote:
Originally Posted by crxb5 View Post
not to kill your vibe... but you are spending a lot of your time making repairs on cars which are not worth it.


According to your post you spent 56 hours a week for 23 weeks which is roughly 1200 hours of your labor. I charger $65 dollars of labor for repairs I do for customers. So I would be charging someone $78,000 to do what you did (for the dodge)... not saying it would take me that long just trying to put this into prospective. The van is not even worth 3k unfortunately... AAllocate your time wisely...
No harm done. The van was done somewhat out of nessecity and some sentimental value. In the end I was able to build a new vehicle for less than 7000 parts and materials. I don't remember the exact figure it was a couple years ago but it wasn't much money in terms of what I got out of it. Anyways what's done is done. As far as the Saab I did buy another Saab and this rusted out one is going to just be a project car. I'm renovating my house and the car is a break from the house but I still stay productive. Besides the Saab I bought is in too good shape to drive in the winter.

The van was something though. The damage wasn't something an average shop would even dream of repairing regardless of cost. Few parts had to be made on a computer and fabricated using NC. Yeah could have been done by hand, but would have taken more time and I had the design and FEA suite at the time so I used it. The van is great though. I'm not exactly wealthy and I'm highly skilled so I just fix the stuff rather than replace. I don't like waste. Yup there is a point to let go, but I seldomly get there.

I have an old Mercedes I'm restoring and you want to talk about crazy I'm in at half the vehicles MSRP in parts alone, but I enjoy the work and at the end of the day I more than earned it. Not like the old rich people that got luckly on an insider tip and bought theire car and goes around preaching about earning and hard work...

Anyways thanks for your advice. From a business perspective you are absolutely spot on, but something someone does as hobby it's inapplicable.

As far as the time to fix the van. It would have probably taken you the same length of time. Many people that are familiar with my project are amazed that it was actually don't so quickly and in a driveway in the burbs with few tools. Without pulling up the carpet it's difficult to tell it was even repaired! Approximately 200lbs of metal was replaced that fell victim to rust.
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  #5  
Old 11th October 2018
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swedespeed7 swedespeed7 is offline
 
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Nice work. You should be super proud of everything you've done!
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Past SAABs: '93, '94, and '95 9000 Aeros, '01 Viggen, '09 2.0T SS
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  #6  
Old 11th October 2018
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300sdl 300sdl is offline
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Quote:
Originally Posted by swedespeed7 View Post
Nice work. You should be super proud of everything you've done! <img src="https://www.saabcentral.com/forums/images/smilies/thumbsup.gif" border="0" alt="" title="ThumbsUp" class="inlineimg" />
With my last restoration I'm very satisfied and I posted daily updates onto a forum when I was restoring that van as a means to help others and to be social I suppose. I did make the CAD files and technical drawings public for those who are in same situation and decide to do the repair.

Now as far as Saab #1. I haven't done a thing to it since I started this thread. I've been super busy renovating my home and barely find the time to work on my summer Saab. My Mercedes that I am restoring and it's thousands of parts are locked in storage and have no time to work on it either &#x1f61e;. I was in the process of collecting parts then was going to start slowly restoring the car. Still will just might be a while.

I finished putting a shower in the house among many other things and I'm taking a break since I've been at it for months. So I'm getting some things done to the summer Saab. I put all new Hella/Pagid brakes on (car had its original brakes at 146k). I'm going to be restoring my headlights again, have to replace seals on chain tensioner, oh I must repair the alarm siren..., have a center flex pipe to replace, have to get the damper for the rear control arm, need 4 new tires. Eventually need new rims (bent), but one step at a time. I do have some body repairs to do in the dog legs and have some PDR to do around the car.
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