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Discussion Starter · #43 · (Edited)
Finally knocked out temp issues today!

Temp gauge was failing sometimes, and even when it was working it was reading slightly cold depending on weather. So I knew it was the temp sensor and thermostat. First time doing this for any car but it was quite easy! Lesson learned: never be scared to try new things :)

Old one out:
Hand Automotive tire Motor vehicle Hood Automotive lighting


Before putting the new thermostat in, I put in a new genuine temp sensor.
Liquid Light Fluid Finger Automotive tire


My 3/8th socket didn't fit the electrical connector part:
Hand Automotive tire Finger Gesture Thumb


So I had to buy a new 1/2 inch socket which fit perfectly:
Hand Finger Automotive tire Thumb Wood


With the new sensor in, I put in the new thermostat making sure to have the breather hole at the top:
Motor vehicle Hood Automotive tire Fluid Finger


Now my car temperature woes are (almost) all taken care of! I still need to do the coolant bypass valve because i have a slow leak from there. I am thinking of doing the coolant bypass valve delete mod. Sounds like a decent idea so I don't have to deal with it ever again.

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Discussion Starter · #44 · (Edited)
Finally restored the Xenons I got a few months ago! I went with the Maguiar's kit: https://amzn.to/3MAkieV

They were pretty hazy so when I first got them, I gave them a light polish but this time I wanted to do it better. To better test the kit, I sanded the driver-side lights with some 600 grit. Also, it's good to do if your headlights are yellow. (in dire need of new corner lights and side grills lol)
Land vehicle Car Automotive side marker light Vehicle Vehicle registration plate


The kit comes with a 1000 grit, 3000 grit, buffing pad, plastic-x and a sealant.
Bottle Liquid Bottle cap Cosmetics Fluid


Liquid Tire Automotive tire Fluid Finger


Fun project for the kid since it's hard to mess this up :)
Automotive parking light Car Vehicle Automotive lighting Motor vehicle


This is after 1000 grit:
Automotive parking light Car Vehicle Grille Automotive tail & brake light


This is after 3000 grit
Automotive parking light Grille Hood Automotive lighting Automotive tire


After polish and sealant. Amazing results for $25!
Automotive parking light Automotive tail & brake light Car Vehicle Grille


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Discussion Starter · #45 ·
Added some color to the interior in the form of LED foot lights. They are RGB but I plan to keep them green. The brightness is also adjustible. At the brightest setting it gets distracting at night. Turning it down makes it perfect.

Vehicle Car Green Steering part Motor vehicle



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Discussion Starter · #46 ·
Added more color: Illuminated shift knob!
I had to cut the shift rod which I don't prefer but hey you gotta live sometimes. I wired it through the cigarette jack. Perfectly matches the other interior lights :)
A new shift knob is such a simple change but it changes the feel of the car.
Watch Automotive lighting Clock Amber Gas


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Discussion Starter · #49 ·
I went to the junkyard the other day, and although there was no 9-5, I did find some little things. One step closer to perfection!

ng900 spotted! This thing was fully loaded, with Viking wheels (with center caps inside), mint black leather seats, bottom end, top end and red DIC in the trunk, cd changer, etc. It was sad seeing it here.
Wheel Tire Automotive side marker light Car Automotive parking light


Here is what I grabbed. I can finally charge my phone in the car now lol. Unfortunately, the shift boot and trim wasn't exactly a fit so off it goes to the parts bin.
Grey Bumper Gas Safety glove Asphalt


Car Hand Vehicle Gear shift Motor vehicle


I also started with my sharktooth bumper. I thought I could repair it with some basic skills but after doing some research, I quickly found out that a repair like this is very difficult, even for pros.
Hand Hood Automotive lighting Bumper Finger


So I removed all the grills and fog light assemblies
Tire Automotive tire Automotive lighting Hood Wheel


My son helped me clean them :)
Automotive tire Tire Wheel Reptile Toddler


Plastic stapled a bunch of the broken slats in the lower grill
Wood Bumper Automotive exterior Gas Metal


Not perfect, but all good now!
Wood Automotive exterior Gas Metal Bumper


The other issue with the bumper was that it had a pretty noticible bulge in the front.
Automotive lighting Hood Motor vehicle Petal Automotive tire


So with this, and the other irrepairable damage, I decided to cut all the broken parts off
Hood Motor vehicle Bumper Automotive exterior Gas
 

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Discussion Starter · #50 ·
Then made the same cut on my bumper (RIP base model bumper. May you be reborn as an aero bumper!)
Hood Automotive lighting Motor vehicle Window Vehicle


Hot stapled at the inner sides like so:
Vehicle Grille Automotive lighting Hood Motor vehicle



Now the results. The body line matches 99%. I was very happy with the outcome considering all of this is very new to me. I've never even used a dremel before lol

Automotive tire Hood Automotive lighting Motor vehicle Automotive design


Grille Motor vehicle Automotive lighting Hood Automotive design



Car Grille Vehicle Automotive lighting Hood



Next is the actual body work. If you guys have any recommendation on what to use for "bondo-ing" these together, please let me know!! I am aware that I cannot use bondo since it is not flexible.
 

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Today, I installed the xenons. mostly plug and play as you guys have said
The levelers on the suspension aren't required? Now I'm curious as to how to eliminate the levelers from my system to get rid of the headlight errors I am getting, I have no need for levelers.

On a different topic...what are the wheels that you had on your Viggen?
 

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Discussion Starter · #52 ·
The levelers on the suspension aren't required? Now I'm curious as to how to eliminate the levelers from my system to get rid of the headlight errors I am getting, I have no need for levelers.

On a different topic...what are the wheels that you had on your Viggen?
I guess not? Haha but doing this doesn't auto level at all. I just leveled it at the beginning and it will be at that level even if the rear is low.

My viggen had stock viggen wheels but just painted dark gray. I also had the NG9-3 anniversary wheels for a short time (the twin 5 spoke design)

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Next is the actual body work. If you guys have any recommendation on what to use for "bondo-ing" these together, please let me know!! I am aware that I cannot use bondo since it is not flexible.
Great work!

I think JB Weld plastic stuff is you best bet for the sticking back together stage.

 

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Discussion Starter · #54 ·
Great work!

I think JB Weld plastic stuff is you best bet for the sticking back together stage.

Wow, I didn't know JB weld had something like this. I love their other products. So I can basically use this like hand clay except it can be used like bondo, so I can sand it smooth and put primer and paint over it?

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Discussion Starter · #56 ·
I picked up an Aero parts car!....FOR FREE (minus tow cost lol).

Several months ago, I saw a 2003 9-5 Aero on FB marketplace, it was $3000. But it didn't have keys, no title, flooded to the floor at one point, and it has been sitting for about 4 years. I obviously didn't agree with the price, but I still reached out to see if he would sell me the seats and a few other parts. He wanted to see if he can sell whole first, so I sadly gave up.

Fast forward to last week, the guy messaged me and asked if I wanted it for $1000, still I didn't think it was the right price so I politely declined. After a few minutes of discussion, he asked me if I would take it for free (after 4 years, the family wanted it out of her backyard ASAP). At that point, I had no choice but to take it! Picked up a uhaul, drove 1.5 hours and picked it up! Here she is.
Automotive parking light Car Vehicle Tire Vehicle registration plate


Surprise! It came with keys, although it is not an original. The previous owner bought the key and matching TWICE but he coudln't find anyone with a tech II to get it started. Appearently it cranks.
It also came with more maintenance history than my own car hahaha. Looks like it was well taken care of before it sat for 4 years!
Sunglasses Gadget Eyewear Automotive design Peripheral


Those of you with eagle eyes, feast your eyes on these Aero goodies! As an Arc owner, this is an absolute gold mine :)
Car Vehicle Motor vehicle Automotive design Car seat cover


The first thing I switched over are the door cards. The Arc ones are all gray and bland. The Aero ones have black inserts, I love the contrast.
Product Grey Bumper Automotive exterior Material property


Next, I took out the seats, they were absolutely MINT! This was the highlight of the pull
Sky Cloud Automotive tire Vehicle Motor vehicle



Perfect time to clean out the french fries
Automotive tire Hood Motor vehicle Automotive lighting Bumper


Also permanently fixed the very common sagging seat side covers. Hopefully it will never break again :)
Automotive tire Gas Carbon Fender Metal


Hood Bicycle part Bumper Wood Automotive lighting


Then I replaced the steering column cover. The one from my car (2004) is beat to hell, but somehow the one from 2003 is near perfect.
Automotive design Bumper Personal protective equipment Sleeve Fashion accessory
 

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Discussion Starter · #57 ·
My e-brake cover was never attached to the trim, so it had a big gaping hole.
Car Automotive design Personal luxury car Vehicle Steering part


And finally, the aluminum-look trim and shifter trim
Car Vehicle Gear shift Motor vehicle Speedometer


As an Arc owner, this is a dream come true. For me, the Aero seats were always my halo saab seats. I am so blessed.


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Discussion Starter · #59 ·
I'm jealous of your door cards, my 2004 AERO has just plain gray, no inserts, the interior on my 2000 AERO has tonnes more character then the 04.
I know what you mean, I heard in 2004, they decontented the 9-5 to save cost (and the brand - clearly that wasn't enough lol). So some of the 04-05 trims got the short end of the stick.
 
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