9-5 Rust-eze Build

Thanks for the info. I did look into what it'd take to get trionic to handle compounds and its not much more than a single turbo high HP build. The MAF isnt reliable after 300 some HP so you have to switch to a MAFless tune (MAP sensor). The MAP sensor has to be upgraded to a 4bar version to read the higher boost pressures. Ill also have to replace the factory boost control solenoid because I doubt it will like 50psi (who knows if ill actually get that high)


Luckily, some guy in russia already figured this stuff out on trionic tunning for his twin sequential setup! https://www.trionictuning.com/forum/viewtopic.php?f=22&t=6491


Anyways, I have the motor put together now! going back to stock for break in, then build the compound system.






PS 80s and 90s cars are the best and a Starion is on my list.

Tboy said:

Wow He's Back! I wondered where this project went to....


Glad your back, can't wait to see how this turns out.

Click to expand...

Thanks!

Was gone last week and part of this week for work, so nothing is getting done


Ive started to put the engine bay back together. Still need to paint some brackets and respray clear on the radiator support.



I'm also working on building some jigs for the engine mounts so i can build urethane versions. Bought some 75 Durometer 2 part rubber. hope i got enough.


I have a hunch that the urethane front trans mounts wear quickly because they are stiffer than the stock mounts and take most of the load. All poly should work better.

It's about time for another update....

The tank has been reinstalled along with the brake and fuel lines running to the rear. This was a little more complicated because I was planning on dual walbro 450s for the compound setup. Anyways, its just a single walbro 450 and I had to keep the -8AN lines. There's 10AWG wire from the battery straight to the pump (with a fuse and relay of course).



Maptun tank straps broke as i started tightening them.... scary stuff.




Now for the motor mounts. Here's what the setup for the left engine mount looked like. Basically just a washer mounted to the bottom half, and a bolt with two washers floating in the top.


Assembled, ready for filling



The right engine mount after filling. I built a retaining ring to fully submerge the floating bit in rubber. This one had a jig made as well.



Gutted the rear mount and built a polyurethane mount as well.


Cast some rubber inserts for this mount and machined them down to final fit


I used an aluminum spool gun for the first time on this...it got a little away from me, but itll work well enough.



aaaaaand here they are:

I'm getting back to this project finally. I spent the last couple of years building a turbocharged EFI 1978 Kawasaki KZ650.


Anyways, back to the saab.
Engine harness: I found a used 2002 aero engine harness with half the miles which will fix the hack job I did on the original that had a broken injector connection somewhere (which caused the burnt valve).

Brakes: I'm also working on refurbishing the brakes: I found some cobalt turbo brembos for the front and will use stock calipers on the rear. I'm pivoting from the orange brakes idea and will paint the calipers black. Also needs new handbrake hardware.

fuel system: I shouldve just kept the stock lines, but I'm no longer considering the compound turbos. I think I need to make an aluminum top hat for the pump assembly as I don't really trust the bulkhead fittings in plastic. Also need to find a place to mount the fancy water separator/fuel filter.

turbo: going back to stock for break in. I do have a subaru 19T twin scroll that I will probably build a manifold for though.

Transmission: Install LSD and a few internal upgrades according the the genuine saab page.

Misc: I also bought a blusaab (i think?) that I saw on Facebook once. It taps into the cd changer cable in the rear for bluetooth audio. I did buy a new welder for the bike project: an Everlast MTS 225 ac/dc tig/mig

Plan roughly looks like:
-refurbish brakes so the suspension is ready to go
-replace engine wiring harness
-finish new fuel system...
-Paint doors, hood, bumpers, trunk.
-install bluesaab
-install short shifter
-transmission mods
-reinstall engine etc w/ stock turbo for break in

Thanks for the offer. I will keep the forums in mind when looking for parts.

the seller for the bluesaab was in the UK and picked up a cd harness for me as well. It was a new unit so i believe the project is active to some extent.

A few updates:
I dug out the shifter unit from the car and installed the genuine saab short shifter...A very nice unit but damn those three bolts are tricky.

I also tore apart the shifter linkage to replace the bushings and linkages. Linkages need to be approx 106 and 75mm long and offset 13mm from the M8x1.25 socket in the shifter. right (ss) and left I cant find the proper left/right hand M8 studs, so i will just use M8 allthread and two right ball joints. I don't really see a need to adjust it anyways.

pivot shafts are 14.80mm and 19.80mm OD, housings are 19.0-19.1mm and 24.05-24.15mm ID respectively. 2mm flanges, 10mm overall length. I cant find the exact bushings so i will just lathe some out of aluminum because i have it on hand. grease should prevent galvanic corrosion.

Damn. 5 months since the last post. I've been chugging along as I can but work has been exhausting.

I installed the bluesaab module and cd changer cable in the trunk.

Zinc plated the hand brake parts and reassembled/calibrated the handbrake system. This was lazy home plating so they're a little burnt, but i am working on a little rotissery plater for the future. should be cool.


Repaired the corroded rear swing arm dampers with the tig welder...nasty cast aluminum was a pain


I also dropped the fuel tank to fix the fuel pump hanger for two reasons:
-I used bulkhead fittings on the nylon top hat and they arent very secure).
-I also gutted the jet pump on the oem hanger so i'd like to be a little more oem with my solution while maintaining the 8AN lines.
I've already done some tinkering and I can stuff the huge 450lph e85 pump in the stock pump bucket with a few tweaks. neato. I've made an Aluminum top hat as well. This needs to be assembled and welded.

Along that line, bought new nickel copper brake lines, a flaring tool and all that stuff to remake the brake lines. I couldn't stomach using the old ones. I havent started making the new lines yet though.

Finished up the install of the short shifter. This entailed replacing the shift rod i bent one time pulling the motor and extending the reverse lock out collar that i cut doing the diy short shifter. What a nice interior for 200k miles. Still need to find the AC seat blanks to install the aux plug and another connector for the ECU can bus.


I started sanding up the hood and trunk. Still needs rock chips filled and primer, basecoat/clear etc.


The last thing i just finished up was painting all of the remaining random brackets and suspension components. I dropped the tarp in the garage creating a one stall paint booth.



Oh, and if anyone needs front aero calipers, i have these nice black painted ones that I dont need as I bought some brembos.