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New to me 9-5 Arc sedan

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Greetings, trying to keep the forums alive. Seems like everyone is migrating over to FB Groups.

(for those who are interested, here is my youtube channel. I try to document everything done to this car) - https://www.youtube.com/channel/UCDxRI82DI5xrL5yKQSxZBog

I recently sold my dream Saab - The Viggen due to moving out of state and couldn't justify taking it with me (long story). The Viggen was my 4th and favorite Saab and I was sad to see it go.

So when I moved, I was on the search for another. I posted on the local Saab FB group with 2 conditions - It had to be manual and under $1,500. I got a few responses. One of them caught my eyes (mainly because it was $850 :LOL:). The owner worked with me down to $700 and it was a deal!

This is my 2004 9-5 Arc. It was sitting for a bit because the previous owner bought a new car and has not been used. It runs and drives remarkably well. Still a mystery to me why the owner let it go for so cheap. Maybe one day I will find out (hopefully I don't haha). It has zero rust, not even a speck! This is new to me because I am from the rust belt. It was weird to see an old car without rust!
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Has 165k miles on the clock
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It is indeed a manual :p
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The first thing to do was to give it a good exterior wash. Body panels are in excellent shape, I could see no dings or dents, just a few scratches in the common places.
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Next on the list is a good interior detail. It needs it badly haha.

I am also documenting the progress on my YT channel.
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Discussion Starter · #25 ·
Finally replaced my cup holder today. I never use it but it always bothered that it was broken!
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I didn't know you had to open up the entire dash panel. It was fun but tedious. Broke tabs and cracked the dash a little. oops :)
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I found the culprit! 1 ball was broken. I guess this is why most cup holders fail.
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The other culprit. This gear was too free and it was causing the cup holder to come out too fast.
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New one is in! :)
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It's a very small thing but I feel good knowing that onemore thing is restored to its former glory. AND I got to learn how it all works inside. I had a very good time with this one. Video link below!
 

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2005 Saab 9-5 Aero Sedan '98 corolla until my 9-5's engine is finished:'~((
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Finally replaced my cup holder today. I never use it but it always bothered that it was broken!
View attachment 287731

I didn't know you had to open up the entire dash panel. It was fun but tedious. Broke tabs and cracked the dash a little. oops :)
View attachment 287732

I found the culprit! 1 ball was broken. I guess this is why most cup holders fail.
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The other culprit. This gear was too free and it was causing the cup holder to come out too fast.
View attachment 287734

New one is in! :)
View attachment 287735

It's a very small thing but I feel good knowing that onemore thing is restored to its former glory. AND I got to learn how it all works inside. I had a very good time with this one. Video link below!
I just really really wish they had steel components and steel ball joints etc. Could be an amazing design but it's just too flimsy!
 

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Discussion Starter · #27 ·
I just really really wish they had steel components and steel ball joints etc. Could be an amazing design but it's just too flimsy!
I have a 3d printer and I was thinking of replicating that ball part but it would probably break again. I was thinking the same thing! I wish someone made steel versions!
 

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Discussion Starter · #30 ·
I acquired some goodies. Sharktooth front bumper and projector headlights. The bumper is in pretty rough shape. I am not worried about the paint chips and scratches because those are easy to fix, but I am scratching my head over the upper grill portion where it is completely detached. Any advice, previous experience, horror stories would be greatly appreciated!

I can think of a few options:
1. Use heat to mould it as best as I can and use strong epoxy, metal mesh back to bond it back.
2. Cut up my base bumper's upper part and merge it with the sharktooth bottom. Cut would be at the black plastic trim line for the best possible match.
3. Just color match it and put the sucker on, YOLO.

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As for the projectors, I saw conflicting opinions online whether they would work on a base model. Some said they are plug and play (I doubt it), some say it will work but with errors on the SID, some say it is impossible and you need level sensors and wiring. Instead of reading about it and giving up, I decided to actually try it for myself. My ideal situation would be to just remove the xenons alltogether and put high quality LED bulbs in as a replacement. We shall see...!
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Without seeing it in person I would guess fiberglass and epoxy for the repair.

Regarding headlights I decided to go with replacement halogen headlights (eBay purchase) and quality bulbs in order to pass a safety inspection and get the car licensed, I will eventually clean up the foggy plastic lenses on the xenons and fine tune on the levelers etc over time.
 

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The xenon lights are plug and play on the older non-xenon cars. They just require some work to get angled correctly. You can cut power to the leveling motor at the highest setting and then manually adjust the rest of the way.


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Discussion Starter · #33 ·
Today, I installed the xenons. mostly plug and play as you guys have said :)

Look at the difference!
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Did a quick polish before leveling them.
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My best friend WIS
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leveled according to WIS.
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on the road comparison
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Video summary:


overall, 1000% happy with the conversion!!!

next up is restoring this rough looking sharktooth bumper. Stay tuned!
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Discussion Starter · #34 ·
For passing 500 subs on my channel, I am giving away three 3d printed cup holders for the NG9-3! Very easy to enter, no scammer bs! I really just want to give back to the viewers, including the saabcentral people. See video for details.
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Discussion Starter · #35 ·
Made a small improvement today.

Side marker lights have seen better days.
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Instead of replacing them with stock ones, I took a risk on some sequential ones from China. These are made for similar year Opel Astras. They are not a direct fit. The inner housing is much smaller than the stock one, so I used outdoor rated double sided tape to stick it on. Also helps prevent water getting into the hole. Theres been several heavy rain days and they are holding up just fine!
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Video summary:
 

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You do not have bottom seal in original, that's why it leaks.
Do not be surprised if new stops working in near future.
 
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