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Derek
V4 Guru

United Kingdom
1825 Posts

Posted - 07 Sep 2017 :  11:04:10 Show Profile Reply with Quote
Burdizzo?
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72sonett3
V4 Fanatic

Spain
240 Posts

Posted - 07 Sep 2017 :  17:00:44 Show Profile Reply with Quote
quote:
Originally posted by Dynorog
...
I'll get hold of some 1.5 mm plate as martin suggested and fab up a new plate.

I had to repair this exact same spot in both my '77 96 and '98 95.

First I cut out the rotten sections like you did and cleaned the edges to bare metal.
Then I traced the size and shape of the hole on a piece of cereal box card board and used that as a template to cut the shape out of a flat metal sheet, and bent it to the shape of the hole in the body.
Then first tack welded it in place followed by continuous butt welds (= without overlap) all around, not all in the same spot but spaced about 10 cm around the edge to avoid build up of heat.
Then some cosmetic grinding and shaping of welds where needed, then primer and finally under body coating.

Remove the carpets and rubber cover of the wheel well in the interior before you start welding... !

--
'72 97
'77 96L conv.
'79 96GL (LPG)
'83 900i (LPG)
'95 900SE conv.
'99 9-3T
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Dynorog
V4 Fan

United Kingdom
119 Posts

Posted - 07 Sep 2017 :  18:26:29 Show Profile Reply with Quote
quote:
Burdizzo

I think my wife will use it as one if I spend any more time working on the car!

Dynorog
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deggsie
V4 Fanatic

United Kingdom
306 Posts

Posted - 07 Sep 2017 :  18:32:35 Show Profile Reply with Quote
Originally posted by Dynorog
Burdizzo - I think my wife will use it as one if I spend any more time working on the car!


Not a term I was familiar with, so had to look it up ! A tool for nuts of a different kind, I see (although there is also an Italian wine of the same name)!

___________________________
Saab - beyond the conventional !

Edited by - deggsie on 07 Sep 2017 18:51:05
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Dynorog
V4 Fan

United Kingdom
119 Posts

Posted - 08 Sep 2017 :  18:45:09 Show Profile Reply with Quote
Thanks for the tips Martin.
Why did you go for a butt weld instead of the lap?
Cheers

Dynorog
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72sonett3
V4 Fanatic

Spain
240 Posts

Posted - 09 Sep 2017 :  16:50:20 Show Profile Reply with Quote
The overlap will be a source for corrosion, specially in that area.
I prefer butt welds, even if it may be a bit more difficult to do, but after some trials you will get the voltage and current settings right.

--
'72 97
'77 96L conv.
'79 96GL (LPG)
'83 900i (LPG)
'95 900SE conv.
'99 9-3T
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Dynorog
V4 Fan

United Kingdom
119 Posts

Posted - 09 Sep 2017 :  19:02:11 Show Profile Reply with Quote
OK, thanks Martin
Cheers

Dynorog
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RhysN
V4 Fanatic

United Kingdom
212 Posts

Posted - 15 Nov 2017 :  17:18:27 Show Profile Send RhysN an AOL message Reply with Quote
I had a very pleasant afternoon visiting Roger and his project. It's almost enough to frighten you (me) off when I see how much he has had to do on a car which obviously seemed pristine in the first place. He is a real enthusiast, and a thoroughly "good bloke , or good bugger". (High praise in the Antipodes)
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Dynorog
V4 Fan

United Kingdom
119 Posts

Posted - 04 Mar 2018 :  18:00:11 Show Profile Reply with Quote
Thanks for the complement Rhys.

Can,t get much welding done at the moment so I'm back in the garage and trying to sort out the mechanicals.

Acquired a pair of rebuilt heads but when I was cleaning the faces up came across this.




Each Head has the word FEILD stamped on it together with a number
17 91 7 and 17 91 8
Anybody come across this? an engine builder vanadle or dyslexic farmer? Then again my spelllings not too hot.Or am I showing my ignorance of a other languages?

Anyway, new Balance shaft and cam shaft bushes renewed,cam,balance and crank shafts back in. Timing gears on.




Feel like I'm going in the right direction now.It's about the only thing I can feel after spending two days in that garage!
Got to get back on the road this summer.

Cheers

Dynorog
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Dynorog
V4 Fan

United Kingdom
119 Posts

Posted - 02 Jul 2018 :  10:21:20 Show Profile Reply with Quote
Made some progress since March and have attached photos.
3 inner wings refurbished, Front calipers new pistons and seals.
New rear wheel cylinders , springs etc.
Engine rebuilt - balance shaft bushes, cam shaft bushes,standard rings put in after honing cylinders.(Cylinder dias seemed ok from measurement as did big end and crankshaft journals.Replaced big end shells.All seals etc.

I then got distracted and started to build engine test bed.
Finally finished it on Saturday and started up engine.Only issues so far are leaking Thermostat housing( I put that rubber sealing ring in) and oil pressure reading 65 psi which seems high but the engine was running very fast and without silencer so not had opportunity to check properly as I didn't want to upset the neighbours too much.


















Dynorog
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melle
V4 Guru

United Kingdom
2603 Posts

Posted - 02 Jul 2018 :  17:03:54 Show Profile Visit melle's Homepage Reply with Quote
Good progress on the car Roger and I bloody love your engine test bench!

www.saabv4.com
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72sonett3
V4 Fanatic

Spain
240 Posts

Posted - 02 Jul 2018 :  21:16:46 Show Profile Reply with Quote
How is yours coming along??

--
'72 97
'77 96L conv.
'79 96GL (LPG)
'83 900i (LPG)
'95 900SE conv.
'99 9-3T
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melle
V4 Guru

United Kingdom
2603 Posts

Posted - 02 Jul 2018 :  21:50:03 Show Profile Visit melle's Homepage Reply with Quote
Slowly but surely:



www.saabv4.com
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Dynorog
V4 Fan

United Kingdom
119 Posts

Posted - 15 Jul 2018 :  17:14:56 Show Profile Reply with Quote
Its a Damn good job I spent some time building the test bed.
Had a leak on the rear core plug after some time running.
I had been a bit worried about it as I had renewed it, using the proper tools to take out the old. (Lump hammer and small chisel) and caught the recess. It looked like it had previously been damaged and I had taken out some more.End result about 25 percent missing.I was going to separate the gearbox again anyway to renew the thrust bearing. I took out the plug and renewed it again, this time with loads of Wellseal and renewed the thrust bearing.So far so good, if it still leaks I'll throw in some K seal to the system.
Renewed points, plug, dizzy cap and rotor arm.Set dwell angle and retimed with strobe light with great difficulty. I ended up doing the static timing and then checking with strobe and it was spot on. When using the strobe every time I got it to 6 degrees BTDC and tried to clamp up, the engine raced and the ignition advanced even further.I think there must be something amiss with the dizzy weights. Any other ideas?
A couple more photos.


Cherry Bomb "silencer" added to convince neighbours that I'm trying to keep the noise down.



Gearbox on its' trolly section of test bed.

Dynorog
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melle
V4 Guru

United Kingdom
2603 Posts

Posted - 16 Jul 2018 :  18:40:08 Show Profile Visit melle's Homepage Reply with Quote
Clever idea to make a separate gearbox section.

With that exhaust you better change your user name to "Asborog"!

www.saabv4.com
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