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 Home-made special tools Please add yours!
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melle
V4 Guru

United Kingdom
2468 Posts

Posted - 02 Feb 2017 :  14:15:13 Show Profile Visit melle's Homepage Reply with Quote
I love making and adapting my own tools, especially since Saab factory special tools are no longer readily available (or if they are, affordable). I hope in this thread we can collect a selection of forum members' home-made Saab V4 special tools, either copies of factory tools or your own inventions. Please post additions in this thread or PM me a photo and I will update this post. Different versions of the same tool welcome. Please credit the maker (preferably with a www link) if you add tools that are not your own! All tools ordered following the factory manual/ parts book. I'll dig out some more of my own next time I'm in the workshop. If people find this useful, it might be an idea to "sticky" this thread?

Engine
Balance shaft bearing drifts


Cam shaft bearing drift


Combustion chamber pressure adaptor for changing valve stem seals with heads in situ, Euro air line connector welded onto a spark plug


Crankshaft lock (with flywheel installed, made from C900 flywheel ring gear)



Crankshaft lock (without flywheel installed, screws directly into crank)


Engine test bench (in progress, will update when done)


Engine lifting bar (M10 eyes for lifting engines with heads on using threads above exhaust manifolds, M12 eyes for lifting engines without heads using head bolt threads closest to exhaust manifolds. Extra eye on bar for gearbox levelling strap/ chain.)



Engine lifting cradle



Engine trolley, based on a design by Jack Ashcraft, made from 2"x4" timbers



Heads overhaul parts organiser


Jetex lower exhaust nut spanner, shortened 15mm spanner


Porting templates find cutting files here: http://www.saabv4.com/index.php/engine-gaskets/sportrally-templates/



Tappet removal tool, made from a tent peg



Electrical system


Transmission
Clutch alignment tool


Release bearing position gauge



Transmission oil filler neck, made from 12, 15 and 22mm copper pipe and a brass fitting



Brakes


Front assembly, column, steering shift gear


Suspension, wheels
Bead breaker




Spring (de)compressor, made from M20 threaded rod and 96 rear upper spring seats




Body


Instruments, accessories, heating system



www.saabv4.com

Edited by - melle on 30 Jun 2017 18:28:10

Dirtbiker
V4 Mad

United Kingdom
613 Posts

Posted - 02 Feb 2017 :  15:59:56 Show Profile Visit Dirtbiker's Homepage Reply with Quote
Great idea for a thread!
I partially rebuilt the engine that is currently in the 96 (heads rebuilt and rods and pistons out) while living in a student house. I cordoned off the bay window area and laid everything out. I had all the valve gear laid out in order and decided to take it upstairs for safe keeping but tripped and dropped most of it. We could only find seven valve springs...
The eighth turned up a couple of weeks later as the bag of Tate and Lyle sugar that had been on the floor neared the bottom, someone had a nice surprise in their brew!
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john-saab
Administrator

United Kingdom
2665 Posts

Posted - 02 Feb 2017 :  17:54:52 Show Profile Reply with Quote
Camshaft bearing drift..

Balance shaft bearing drifts..


'73 96 (Vernon),'74 95 (Veronica)plus 4 other 95's and 2 96's
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melle
V4 Guru

United Kingdom
2468 Posts

Posted - 02 Feb 2017 :  18:22:28 Show Profile Visit melle's Homepage Reply with Quote
Thanks John, added to the opening post.

www.saabv4.com
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Zagato
V4 Mad

United Kingdom
755 Posts

Posted - 02 Feb 2017 :  19:40:48 Show Profile Reply with Quote
Well look at this beauty, the mark two version of the Defender drain hole unblocker, complete with ergonomic handle now available on E Bay as a coat hanger DIY kit with easy instructions!




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john-saab
Administrator

United Kingdom
2665 Posts

Posted - 06 Feb 2017 :  19:57:52 Show Profile Reply with Quote
I have deleted all of the irrelevant posts so that this thread can carry on as intended.
I will add a post to the "how to add photos" section later.

'73 96 (Vernon),'74 95 (Veronica)plus 4 other 95's and 2 96's
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stevebod
V4 Fanatic

United Kingdom
307 Posts

Posted - 07 Feb 2017 :  12:52:33 Show Profile Visit stevebod's Homepage Reply with Quote
This is a useful thread.
I don't have much to offer, but I did make this clutch alignment tool once which worked OK.

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stevebod
V4 Fanatic

United Kingdom
307 Posts

Posted - 07 Feb 2017 :  12:56:07 Show Profile Visit stevebod's Homepage Reply with Quote
Oh and I made this engine stand based on a design by Jack Ashcraft.


For reference the timbers used were 2" x 4".

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Zagato
V4 Mad

United Kingdom
755 Posts

Posted - 07 Feb 2017 :  16:50:24 Show Profile Reply with Quote
That's a better design than mine for the engine. I just made a flat trolley I could lay stuff on including me under cars. I put a block of wood under the end so it,s not resting on the timing gear. It,s not as stable as yours!




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john-saab
Administrator

United Kingdom
2665 Posts

Posted - 07 Feb 2017 :  17:39:43 Show Profile Reply with Quote
quote:
Originally posted by stevebod
This is a useful thread.
I don't have much to offer, but I did make this clutch alignment tool once which worked OK.




If you find a scrap gearbox take out the input shaft and you the perfect clutch tool..made for the job.

'73 96 (Vernon),'74 95 (Veronica)plus 4 other 95's and 2 96's
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Borstlap
V4 Fanatic

Norway
270 Posts

Posted - 31 Mar 2017 :  23:16:10 Show Profile Reply with Quote
The lifting cradle:





I am not so keen on using the exhaust studs for lifting. Though the cylinder heads are sturdy I don't want to take the risk of warping because of the weight of the engine. So I came up with this device. It screws onto the engine block on several places, spreading the load. With the chains on top the angle of lifting can be adjusted. I have used it on the Sonett and lifted out the engine-gearbox combo. With an extra strap around the tail of the gearbox you have full control and you can lift the engine out and in again by yourself. In addition I have two separate trolleys that can support both parts. Engine and gearbox can easily be separated and joined using the trolleys.

Alex
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melle
V4 Guru

United Kingdom
2468 Posts

Posted - 01 Apr 2017 :  20:29:50 Show Profile Visit melle's Homepage Reply with Quote
Added to the collection in the opening post. Looks way over-engineered to me Alex! I use the threaded holes on top of the exhaust manifolds for M10 lifting eyes and a lifting bar that clips into them. Will photograph my lifting gear next time I'm in the workshop.

www.saabv4.com
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melle
V4 Guru

United Kingdom
2468 Posts

Posted - 30 Apr 2017 :  19:01:44 Show Profile Visit melle's Homepage Reply with Quote
Engine lifting bar added.

www.saabv4.com
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