Jump to content

Saab 96L - An Occasional Series.

Recommended Posts

Moving on to the front left wheel arch.


This strange looking patch is at the junction of the inner wing and the front valance.


What lies beneath ☹️


Tidied up.


Welded up.  It could be neater but is strong.

I realized that the two valance end are a mix of thin patches and filler so there will be some welding needed there too.

Link to post
Share on other sites
  • 2 weeks later...


After a good look at the valance I realised that the end was mainly some odd shaped patches. It all got chopped off to reveal this:-IMG_20210102_165200.thumb.jpg.8bdbdf67697ecf3960d4321ff200703b.jpg

It had a quarter inch of filler over it before I started. I put a patch in the valance edge, then opened out the main rot hole.IMG_20210106_165613.thumb.jpg.b002b21655625685663fb9085a4edd9a.jpg

Next I tidied up the rusted brackets inside and got rid of the ragged pitted bit on the upper corner.IMG_20210109_165933.thumb.jpg.bd7b41f2a22b188a686fbbd01c77d048.jpg

Then made a patch and held it in place with intergrips.IMG_20210110_155002.thumb.jpg.b9943fb9ec2f484a5bd05212bc5cb4cf.jpg

I lapped the patch slightly under the engine bay floor by a quarter inch.

Then welded it in.IMG_20210112_133055.thumb.jpg.ab2e706a95b22e9fb7c27393c29130f0.jpg

I'm still not in practice with my welding, but the linisher is my friend. And I can always fill any small hole with weld. You can see that I added a narrow strip on the bottom of the inner wing where it laps around the valance. I treated all the bare patches and also put some Hydrate 80 on any surface rust on the inner wing.IMG_20210112_174319.thumb.jpg.5ef15df595ae3eef85b0376d59da7834.jpg

Also I took the opportunity to clean and paint the shock :-IMG_20210112_133824.thumb.jpg.7cf9f8e6b6c40254c14b78ad407ccf78.jpgIMG_20210112_154345.thumb.jpg.d9a47535e7d6bec357219ff55465a469.jpg

And the bumper bracket.IMG_20210112_170225.thumb.jpg.bdfad62f2b768071f4806d19ed84f7b1.jpgIMG_20210112_172721.thumb.jpg.a8ac9b55ceea59438ca67f664ade45eb.jpg

This work was spread over my spare time in the last week.

Next job, seam seal the repairs inside the engine bay and under the inner wing, then more zinc primer.

Link to post
Share on other sites
33 minutes ago, Tim_E said:

This is epic. I can't imagine all this hidden rust makes you happy but the thread is very pleasing to see it get done so lovingly.

I'm not too upset by this amount of rust. And it being such an interesting car helps. I wouldn't do it for an Escort.😁

Link to post
Share on other sites
10 minutes ago, artdjones said:

I'm not too upset by this amount of rust. And it being such an interesting car helps. I wouldn't do it for an Escort.😁

There are some who would for a mk1 or 2 Escort perhaps but ha no I agree, this is a special car needing some special attention. 

Amazing work, I'm glad you're unphased.

Link to post
Share on other sites

Seam sealed on Wednesday.IMG_20210113_171140.thumb.jpg.cd95081bd48f571a500f3be55d2810d5.jpg

Two coats of zinc primer yesterday and this morning.IMG_20210114_174605.thumb.jpg.364ec8378f1409a3b2afb156844dd5d0.jpgIMG_20210115_120844.thumb.jpg.8bdf80f8bc4cf9db4937c402aeb4e7f1.jpg

Then on to the sills.IMG_20210115_121016.thumb.jpg.4e4098a8578ba50ed3a0c06a832b8b19.jpgIMG_20210115_121034.thumb.jpg.fc8a750822efe1e5f9b8c7742d7ccdd9.jpg

The front half was a bit crusty. On the last picture you can see the rear jacking point. I forgot to take a picture of its comrade on the front, but unfortunately the sill was holed behind it. So I cut it off.IMG_20210115_135708.thumb.jpg.9977d3bdd82a2163234f4c225f634784.jpgIMG_20210115_135858.thumb.jpg.e172f9e0e238c223555da0c7ed19ec9f.jpg

These things cost ££ so I ground the sill remains off it and treated it for later reattachment. IMG_20210115_145419.thumb.jpg.98e4760dd5408a2f92b4edaec7a328d5.jpgIMG_20210115_145958.thumb.jpg.57a201d5260ae1e2eb79677123411ec4.jpg

Then noticed the edge of the floor had some small holes.IMG_20210115_121851.thumb.jpg.87032c12547731e2f90c04e981aa582b.jpgIMG_20210115_194818.thumb.jpg.76ad879ea64aeb6be32b0ee4ef0ba7c7.jpg

And finally extended the hole in the undersill up to the wheel arch. It will make for a neater join. And there are  two lap jointed patches on the sill further back and I don't want the underneath of the car to look like a patchwork quilt. Although I feel a temptation to cut those patches off and butt joint some new ones in.IMG_20210115_165018.thumb.jpg.cf732e72084d196fb0679d49e8efa24d.jpg

The only thing holding up progress now is a lack of sheet steel. I have enough for the strip on the edge of the floor, but I need some 1.5mm sheet to replace the piece of sill(96 sills are very thick), and I'm wondering where to get it during lockdown. I have some cheques to pay in in town next week, so I may get a chance to go to the local sheet metal worker/tractor repairer to see if he has a small offcut.


Link to post
Share on other sites
  • 4 weeks later...

I still had a couple of scraps of steel left so l made a patch to fill in the front half of the hole in the floorIMG_20210118_172343.thumb.jpg.d5f811afea7236e6d6998a54d2f6e68d.jpg

Then seam welded it.IMG_20210119_142612.thumb.jpg.5ddecb3275b7199061b31f9d4a0ff58e.jpg

I hate overhead welding. 

I filled in the back half as well.IMG_20210120_192103.thumb.jpg.5ed139dccd57740f4bb5869b47cb7229.jpg

Next bit was to replace the strip of steel that had to be cut out of the sill to get proper access to the floor.IMG_20210120_175528.thumb.jpg.ec10a6d5364cef91f0c9289c48bcdbce.jpg

Note BX jack.

After that the next stage was to replace the front 8" of sill.IMG_20210202_163218.thumb.jpg.44fc1617cb67e067e061071beb21e35d.jpg

I made a stupid error here. I should have welded the jacking point on to the patch rather than waiting until the patch was attached to the car.

It proved difficult to get the jacking point welded on neatly later, whereas I could have plug welded it on from behind on the bench.IMG_20210203_143911.thumb.jpg.4b93478cd9f4140031bd7e70996ba2ac.jpg

There's a very small mudflap on a bracket on the back of the sill on these and in getting the rusty bracket off I found two tiny holes. I opened them back to solid metal with a step drill.IMG_20210204_131110.thumb.jpg.1226cb63a4f0e459313c3a7d2a49f46f.jpg

Then put in two tiny patches ground to shape. A good way of getting these small pieces exactly where you need them to go is to weld a piece of coat hanger wire to them, then you can steady them with one hand while tack welding them in.IMG_20210204_153420.thumb.jpg.0c75e98fc3683353a4308bbba51a6d7e.jpg

They were welded all around, ground back , and a new bracket made and attached.


Then the whole sill was treated, seam sealed and zinc primed.IMG_20210207_144746.thumb.jpg.13a16db28c771d315f6b204b95d53e26.jpg

It's a bit of a patchwork quilt, as there's two other welded patches under there  done many years ago. If any other work is ever done under there I will buy a whole undersill and replace everything. So, now to side two.

Link to post
Share on other sites
  • 2 weeks later...

Now moving on to the right hand quarter panel. Crusty at the top.IMG_20210212_115724.thumb.jpg.70fde4060c1c67c2219e259cc3e78f53.jpg

Also crusty at the bottom.IMG_20210212_115732.thumb.jpg.ccf99631251e8c012487edce00126eef.jpg

Rust removal at the top left a large hole.IMG_20210212_132509.thumb.jpg.1d4e2d2c357feafee15cc2ccffb8e278.jpg

I decided to work from the outside in. The flange that joins the wheel arch front to the quarter panel was non existent at the top and as it curves in two dimensions is fairly difficult to make.

So first I made a patch to fill the hole in the back of the quarter panel and tacked it into place temporarily.IMG_20210213_160240.thumb.jpg.9a9afed59819ed6b00ca37fc5ba87529.jpg

Then made a slotted flange piece that curved in two directions.IMG_20210213_162044.thumb.jpg.fa40f0519f6300dabd0331df9bd13b36.jpg

Then ground the patch off and joined the two bits together.IMG_20210213_174649.thumb.jpg.913da566854506441d9b084cbb8f135e.jpg

Next step was to make the inner flange to match and weld in onto the car.IMG_20210215_164027.thumb.jpg.fa613c7c89854b5d2d96820a7ed24094.jpg

Then tack the outer piece in place.IMG_20210216_114843.thumb.jpg.2f169f4d59dd3027efd22cb17792f3ae.jpg

Welded it all around.IMG_20210216_120725.thumb.jpg.3256e66d627162da11ddda168c59760c.jpg

Then ground it back.IMG_20210216_123456.thumb.jpg.3a3d5e0858460bce0acec198413932a3.jpg

This was all quite time consuming and I don't think I'll ever be invited on to Welding With the Stars.

Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
  • Similar Content

    • By Zelandeth
      Well I've been meaning to sign up here in forever, but kept forgetting. Thanks to someone over on another forum I frequent poking me about it recently the subject was forced back into my very brief attention span for long enough to get me to act on the instruction.

      I figure that my little varied fleet might bring you lot some amusement...

      So...we've got:

      1993 Lada Riva 1.5E Estate (now fuel injected, as I reckon the later cars should have been from the factory...).
      1989 Saab 900i Automatic.
      1987 Skoda 120LX 21st Anniversary Special Edition.
      1985 Sinclair C5.
      2009 Peugeot 107 Verve.

      Now getting the photos together has taken me far longer than I'd expected...so you're gonna get a couple of photos of each car for now, and I'll come back with some more information tomorrow when I've got a bit more time...

      Firstly...The Lada. Before anyone asks - in response to the single question I get asked about this car: No, it is not for sale. Took me 13 years and my father's inheritance to find the thing.

      Yes, it's got the usual rusty wings...Hoping that will be resolved in the next couple of months.


      Next, a proper old Saab. One of the very last 8 valve cars apparently, and all the better for it. I've driven two 16v autos and they were horrible - the auto box works sooooo much better with the torque curve of the 8 valve engine. Just wish it had an overdrive for motorway cruising...

      Next up a *real* Skoda...back when they put the engine where it belongs, right out the back. In the best possible colour of course...eye-searingly bright orange.

      Seat covers have been added since that photo was taken as it suffers from the usual rotting seat cloth problem that affects virtually all Estelles.

      Then we have possibly the world's scruffiest Sinclair C5...

      Realised when looking for this that I really need to get some more photos of the thing...I use it often enough after all! We have a dog who's half husky, so this is a really good way of getting him some exercise.

      Finally - again, I really need to take more photos of - we have the little Pug 107.

      Included for the sake of variety even if it's a bit mainstream! First (and probably to be the only) new car I've bought, and has been a cracking little motor and has asked for very little in return for putting up with nearly three years of Oxford-Milton Keynes commuter traffic, before finally escaping that fate when my housemate moved to a new job. Now it doesn't do many miles and is my default car for "when I've managed to break everything else."

      I'll fill in some more details tomorrow - I warn you though that I do tend to ramble...
    • By bezzabsa
      Right as you have gathered, the Kudos has arrived at Bezza towers (cheers WOC for that)..

      Looking over her I have noted that arches are fooked 

      Hope to get a hammer to them tomorrow to see if they need sparky stick, or fibreglass and wob..
      NOW... seeing as I'll be doing all 4 arches, and the surrounding paintwork is actually in pretty good condition.
      I intend to do a good old fashioned 80's tidemark, starting at the top of the arches, down to the sills..
      Car is a dark grey - so what colour do you reckon the tidemark should be...
      Really not sure what colour as I know I won't be able to match the original, and it will be rattle canned too..
      Cheers all, will update as and when anything happens to the old barge
      Still trying to find a name for her!!!!
    • By Peter C
      Woke up this morning, had a little time before I had to leave the house for work, had a quick look at what’s new for sale on Retro Rides and saw an ad for a W124 200E manual, located 15 miles from home. I had no intention of buying a car today but I had to have it! I called the seller and arranged a viewing.
      2 x rusty front wings (TADTS)
      1 x rusty rear arch
      Needs a polish
      Tracking is out because new track rod end was fitted for MoT
      Engine has oil leak/s
      Good points:
      It’s a W124 200E!
      5 speed manual transmission
      New clutch
      Brand new MoT
      Superb MoT history
      4 x as new Continental tyres
      Last owner for 15 years, her husband before that for 4 years
      Very tidy MB-Tex interior
      Drives well
      All electrics work
      The dealer kindly delivered the car to my house but I managed a pez station shot on route:

      Remove front wings, cut away rust and apply plenty of wob.
      In-situ similar repair for rear arch
      Clean and polish
      Service engine
      Adjust tracking
      Leave patina and enjoy the car as it is
      I will update this thread once progress is made.









      Hopefully these two will become good friends.

    • By dome
      This evening I venture forth into hitherto unknown lands (Kirkintilloch) to collect my latest acquisition.

      Which, naturally, has issues.

      I have purchased my first line of defence.

      Which appears to have antigravity properties

      More will follow this evening...
    • By captain_70s
      I'm a masochist from Leeds who is running two rusty, worn out Triumph Dolomites as my only transport in rural Aberdeenshire. You might recognise me from various other forums and Facebook groups. Realistically I need to buy a modern car of some sort, but instead I find myself looking at £300 Citroen BXs and Triumph Acclaims on Gumtree and thinking "yeah, that'd fit right in with the rest of the broken cars I can't afford".
      On to the cars, the main attraction being my 1976 1850HL "50 Shades of Yellow" that I bought for £850 and is currently my daily driver, here is a picture of it before I sanded off some surface rust and sprayed it badly in the wrong shade of yellow with rattle cans:

      Within a month of purchase I managed to plant it in to a steel fence backwards after a botched gear change on a wet roundabout and ruined the N/S rear wing, although judging by the other dent that's packed with filler it looks like somebody had already done the same. I also managed to destroy a halfshaft and one of my Sprint alloys (good for an extra 15hp) in the incident, so now it's sitting on it's original steelies but painted black (good for an extra 5hp).
      It's only broken down on me twice. once with some sort of fuel delivery related problem which may or may not have been an empty fuel tank and once when the thermostat jammed shut and it overheated and blew out some O-rings for the cooling system. It has recently developed a taste for coolant and oil which is rather annoying, although it's done 89,300 miles which is about 80,000 more miles than BL engineering is designed to last, I'm keeping my eye on eBay for replacement engines... 
      I tried to keep ahead of the rust a bit by rubbing down the arches and re-painting them, but apparently rattle can paint isn't great when you are spraying it at -5C, it also highlighted how although my car might have been Inca Yellow in 1976 it's now more of a "cat piss" sort of shade. So I ended up with the wrong shade of yellow which has rust coming back through after 5 weeks. Did I mention I'm incompetent?
      The other car is the first "classic" car I bought, so I can't bear to sell it. It's a '77 Dolomite 1300 and it cost £1400 (about £400 too much) and has been nothing but a pain in the arse:

      It looks much prettier (from 100 yards) but that's most due to the darker paintwork hiding the rust. It lives a mollycoddled life in my garage, where it somehow still manages to rust, and is utterly rubbish. 0-60 is measured on a calendar, top speed is 80ish but at that point it uses more oil than petrol, it rarely ventures over 50mph and if you encounter an incline of any sort you can kiss that sort of speed goodbye, along with about £20 of 20W50 as it vanishes out of the exhaust in the form of blue smoke.
      One of the PO's had clearly never heard of the term "oil change" so it developed into brown sludge that coated everything internally with the next owner(s) blissfully pouring fresh oil on top of it. This lasted until about 600 miles into my ownership when there was muffled "pop" from the engine bay and the car became a 3-cylinder. The cause was catastrophic wear to the top end causing a rocker arm to snap:

      As this was my first classic car I'd assumed it was supposed to sound like the engine was full of marbles, it wasn't.
      I put the engine back together with second hand bits declared it utterly fucked and promptly did another 5000 miles with it. After about 3500 of those miles the oil burning started, valve seals have gone so it's been relegated to my parent's garage as a backup car and something to take to local car shows as the 1850 is now embarrassingly ugly. I'm keeping my eye on eBay for replacement engines (deja vu, anybody?) Oh, I also recently reversed it into a parked Ford Fiesta and royally fucked up the rear bumper, rear panel and bootlid. Did I mention I'm incompetent?
      There have been two other cars in my life. My first car, a 2008 Toyota Yaris 1.0 an it's replacement a 2012 Corsa 1.4T. I didn't really want either of them, but it's a long story involving my parents and poor life choices. Ask if you want to hear it!
      So that's a brief summary of my current shite. If you want more pictures or details of anything do say as I've got photos of almost everything I'd done with the cars.
  • Create New...