Build thread: Saab 900 Rally Car

[Topher]

Putting a place holder here. I just purchased a 94 Saab 900 to use as a RallyX car and a Home Depot runner.

I will be working on it with my Saab friends. Once we get it done, hopefully, you guys can make it out to a RallyX and see it in action or participate in the event.

For now all I have is this picture:

http://i8.photobucket.com/albums/a35/VicForce/r7.jpg



Mods will be relatively simple to keep it in the stock class at any event I participate in. Mudflaps, Hella 500s, Koni adjustables, new brakes (if needed) and a custom catback.

Should be fun.

[John2.0T]

nice man!

I've never been to a Rally-X but they definitely look fun :).

Until I get a beater, watching/riding is as close as I will get to participating haha.

[EWAustin]

I saw your title and went OOH!

I was hoping that it was a c900. My Dad sold a c900 turbo a while back to a guy who said he was gonna use it as a rally car. It woulda been funny as hell if you had been the one that bought it.

[CaRJoE0220]

1) Nice project and it will be nice to see it come along. Any pics of cars u use for inspiration. Where is a website on more info. I have been thinking it would be fun to build a rally car, its one of the most pure form of original racing IMO

[Topher]

I saw your title and went OOH!

I was hoping that it was a c900. My Dad sold a c900 turbo a while back to a guy who said he was gonna use it as a rally car. It woulda been funny as hell if you had been the one that bought it.

Eric, you know I considered the classics, but I was concerned with the transmission and I THINK that this will be a bit more reliable. Not for certain, but that is the hope.

And the C900's seem to still command a strong price if you want a solid one.

Let me know if you want to hang out when we do the work on it. Haven't seen you in awhile.

[palmer]

Anyway, I think a 3" cat-back with a gutted cat would be neato. You could throw a flowmaster, or glass pack on it, and it would sound pretty sweet.


You have to have a cat for the "stock class" right?

[Topher]

Let's keep this on topic, k?

Anyway, I think a 3" cat-back with a gutted cat would be neato. You could throw a flowmaster, or glass pack on it, and it would sound pretty sweet.


You have to have a cat for the "stock class" right?

Yup, cat needed. I am not going to cheat the system though. If I get rid of the cat I will just move to the next class.

[JK9K]

Eric, you know I considered the classics, but I was concerned with the transmission and I THINK that this will be a bit more reliable. Not for certain, but that is the hope.

And the C900's seem to still command a strong price if you want a solid one.


The transmission is MUCH stronger. You won't smash it to pieces unless you manage to screw up the reverse gear (not too uncommon, as people like to put it in reverse while the car is still moving forward).

My guess is that you will be fine, and you run a MUCH slimmer chance of busting the transmission compared to a c900.

And yes, the classics are getting to be hard to find in solid shape, and when they are solid they command waaaay too much money in most cases.

The only problem I would think you might encounter is breaking the stock springs and blowing out the stock shocks. But I suppose you can address those issues as they arise.

[palmer]

you asked for it by baiting someone in your original post. :thumbdown:



Again.... he asked for it in his original post. what do you expect?





Any plans to at least take out the back seats or anything? I know you are going to use it to haul Dog...

[CaRJoE0220]

So what CAN you do in a stock class? Can u modify the exhaust as long as it has a cat? or the whole performace aspect has to be the same throughout all cars? Can u at least do some weight reduction? tires? wheels?

[JK9K]

Stock class is pretty restrictive. Maybe topher can post some info about the requirements.

When I autocrossed my SPG I had just replaced the cat with a section of 3" tubing. The was the only thing non-stock about the car, and that bumped me into the "prepared" class.

I suppose its all about what class he wants to be in.

Since rally cross is more popular with the AWD guys (Subies and such) he would probably come out well "for his class" in modified or prepared 2wd, just because there won't be any competition.

I'm not sure how much Topher cares about what class he's in, so that will determine if he wants to do anything to lighten the car at all (which automatically puts you in Modified, which is above Prepared I believe).

[CaRJoE0220]

oh so the stock class has sub classes breaking up like the Audi/Subi with the other guys?

[Topher]

In most forms of motorsports you can do the following in STOCK:

wheels, as long as they are not wider or larger than those offered in any of the OEM configurations

ANY struts (oem, adjustable, etc)

A front roll bar.

ANY dot legal tire (in rallyx) in autox you can use rcompounds in stock

Catback exhaust

Filter panel, no open filter.

My goal is to have it dialed in and do a season or half a season in stock. Then maybe consider stripping it, but realistically, that undermines the whole "utility" aspect of it.

[Topher]

oh so the stock class has sub classes breaking up like the Audi/Subi with the other guys?

No. Drive type.

STOCK
FWD
AWD
RWD

MODIFIED
FWD
AWD
RWD

PREPARED
FWD
AWD
RWD


But this is for rallyx, there are other forms of classing in different race types.

[Champ]

I know this guy is pretty excited!

[Digital K]

stripping it only makes it more utilitarian :D one seat ftw!

[JK9K]

stripping it only makes it more utilitarian :D one seat ftw!

You can haul more 2x4s that way :biggrin:

The crappy thing is I know there is verbage in the rules that say stuff about having the same number of seats as it left the factory with fer certain classes.

But I suppose that's only really important if you want to do super well in your class and whatnot. If you're just rallycrossing and autocrossing for fun then I suppose it doesn't matter what class you're in anyway.

[Topher]

I know this guy is pretty excited!

Thanks again for making the Trek with me.

I gave you Karama points.

[Champ]

Thanks again for making the Trek with me.

I gave you Karama points.
:happydance:

[palmer]

The crappy thing is I know there is verbage in the rules that say stuff about having the same number of seats as it left the factory with fer certain classes.




Zip-ties and baby seats.

[hamradio]

Makes sense. :happydance:

Damnit, I love the happydance emoticon. :happydance:

[JK9K]

Alright, well, I forgot my damn camera, and so did Topher. So, no photos.


But, to update this a bit:

Topher got the car a few weeks back, and he is renting a garage for us to work on it (since his garage is full of stuff from the contractor doing a basement remodel at his place).

So, the car started right up, and seems to run very well, however the clutch was pretty much half engaged even with the clutched pushed all the way in. I was able to start the car in gear and take it for a little spin around the block, but it was clear that something was f&^%ed somewhere in the bell housing.

So, we finally got some time this long weekend to dig into the car. Yesterday we took out the struts and got the sub frame ready to drop, I brought the struts to my place where I will install a new set of Koni adjustable inserts into the strut housings.

Today we dropped the sub frame and popped the transmission off of the car to reveal why the clutch was acting all screwed up. The throwout bearing had actually fallen apart, got all bent up and worked its way into the fingers on the pressure plate! It was interesting, I had never seen one fail like that...it must have been making quite a screeching noise before it gave out.

There was pretty much no sign of the bearings, a few little ball bearings fell out when we unbolted the pressure plate, but the rest were MIA!

We took the oily trans to the spray it yourself car wash and got it looking nice and clean, and that's how we ended the day. We just need to find a place to have the flywheel lightened and resurfaced, then things can start going back together.

I think Topher is ordering new brakes to install while everything is apart.

[EWAustin]

Wow,
That's pretty impressive (throw out bearing)

especially considering that they're always on the pressure place (not disengaging like most clutches)

[JK9K]

Yeah, and somehow physics seems to have failed, as the outer ring on the throwout bearing (the piece that separated from the main body of the TOB) was pushed inside of the pressure plate, which has a smaller opening than the diameter of the TOB.

As you probably know, you can't get a ring/disk to fall into a hole that is smaller than the ring/disk...which is why manholes are round. Anyway I digress, the part that fell off must have been wedged sideways through the fingers on the pressure plate. Pretty impressive if you ask me.

There was very little carnage in the bell housing other than that, in fact, the clutch disk was worn out a bit, but probably still usable. The pressure plate was heat-spotted from being slipped too much, as was the flywheel, but other than that they looked OK. Either way, all new clutch bits will be going on when this is reassembled.

[Topher]

So I was bored the other day... so I began a grillE project.

First picture is the stock grillE, then I separated the chrome portion from the back portion. Grabbed a Dremel and removed the slats and the cross "wing" portion, then I sanded down the portions and used a filler.

I still need to sand the filler down and sand the "chrome" portion and prime/paint. I also purchased some mesh that I will paint black and then see how it looks.

In the process I broke every tab that connected the chrome piece to the back black portion, so I will have to find some way to rig those together.

This was inspired by JK9K's grillE, I think nearly every 9000 is hideous but his grillE (and the mad tight power) makes the car.

http://i16.photobucket.com/albums/b47/campbellca/IMG_6581.jpg

http://i16.photobucket.com/albums/b47/campbellca/IMG_6583.jpg

http://i16.photobucket.com/albums/b47/campbellca/IMG_6585.jpg

http://i16.photobucket.com/albums/b47/campbellca/IMG_6585.jpg

http://i16.photobucket.com/albums/b47/campbellca/IMG_6590.jpg

http://i16.photobucket.com/albums/b47/campbellca/IMG_6587.jpg

[palmer]

Nice!


I hate NG grillEs.



You should just glue the halves together. Get some quick set epoxy, and give it hell.

[hamradio]

I like the stock 9000 grilles with the slats that you cut out.

Keep up the good work. (I'm serious) :thumbup:

[JK9K]

The funny thing about the reaon I molded my grille together and cut out the slats and center bar is because I would not be able to open the hood with a stock looking grille.

I don't have any good up-closer shots of mine, but this kinda gets the point across...

http://i56.photobucket.com/albums/g177/jvkrocak/1995%209000/IMG_1304-1.jpg

It would probably be easier to do on a ng900 like Topher has, since the grille is taller and would probably be easier to mold into one piece like I did with mine.

[Topher]

And... it runs!

JK drove it back to my house tonight from the storage garage.

New clutch solved all the issues.

"upgrades" thus far:

EGR delete
Lightened flywheel
GS Inner suspension bushings
GS Front ARB bushings
Koni adj. (front only for now)
9-3 front springs (sits a bit higher)


Still to be done:
rear Koni
25mm ARB
mount flaps
mount HELLAS!!
2pt subframe brace (JK just has one laying around)
GS Engine mount
Get wheels powdercoated/buy rally tires


Big thanks to Jessop!

The Saab guys will probably trek out for the next gathering at Slim's garage.

[Topher]

Here's the ugly side of the 900.

Also, note the "lifted" front end. Nice. Very nice.

http://i16.photobucket.com/albums/b47/campbellca/photo-1.jpg

Seeing as the EGR shenanigans were removed, but the holes weren't filled (yet), I reek of exhaust fumes. Awesome.


Things I don't like:

Washer pump or whatever doesn't work... very hard to see out of dirty ass windshield.
It feels like a wallowing pig after driving my 9-3ss
It has blue turn signal bulbs
The sound of something metal falling off the car, but having no idea what or where it is or went to
Transmission mount, I kind of sort of launched it off of a snow bank, upon landing, it popped out of gear. Oops. GS tranny bushing should help some.

Things I do like:

I tightened the konis up to full firm (fronts are only ones installed right now), that got rid of the majority of the wallowing pig syndrome
Smelling like I just drove a car
The stupid noise it makes with the four holes in the exhaust manifold
Having a three door that I didn't have to fab

[JK9K]

And just a note, Topher and I raced from about 20mph to 60mph and this thing kept up with his 9-3 pretty decently! Neither car is fast, but I was suprised this thing was able to hold its ground at all.

I bet the sound of metal falling out of the car was either some tool I left in there, or the damn subframe bolt that went missing inside the subframe.

[Topher]

Rally tires are here. Yeah!

http://i16.photobucket.com/albums/b47/campbellca/photo-2.jpg

[dubswede]

holy crap that's a tire.

nice.

[Digital K]

wow, meaty!


I tried to find a suitable "meaty" image....little did I know meaty was a very common term for a beefy vagina :thumbdown:

[Die Frau]

LOL.... nice.

[Topher]

Sweet, another package.

Just got my Hankook contingency sponsorship stuff

http://i16.photobucket.com/albums/b47/campbellca/photo-4.jpg