Saab 99 Turbo part 9 – front section welding

Saab 99 Turbo 1978

The Saab 99 Turbo is proceeding once again – welding as usual…

I had a busy summer and the project was pretty much on hold for a few months. At the moment it looks like I will not be able to put too many hours on the car but the plan is to have all the body work done this winter.

But – at least the floor, trunk area and the rear quarters are done! The one major thing to do is to fix the engine bay area and the windscreen frame. And then there is some smaller stuff like fixing the doors, but they are not too bad.

Rust repairs on the trunk area and floor are now done. I sprayed on some epoxy to keep it from rusting while other sections of the car are done.
Rust repairs on the trunk area and floor are now done. I sprayed on some epoxy to keep it from rusting while other sections of the car are done.
Wheel well area.
Wheel well area.
The spare tire compartment came out pretty nice.
The spare tire compartment came out pretty nice.

Making a welding jig for the front section

We came up with a plan to make jigs to keep the various pieces in the front in correct position while welding. So we constructed jigs for the front end of the fenders and also for the window frame.

Making a welding jig for the front section. This will help keep the fenders in place while fitting everything.
Making a welding jig for the front section. This will help keep the fenders in place while fitting everything.
The windscreen frame bottom section was badly corroded and needed to be replaced. We made jig for it using the water holes as fixed points.
The windscreen frame bottom section was badly corroded and needed to be replaced. We made jig for it using the water holes as fixed points.
Most of the rusty pieces cut away.
Most of the rusty pieces cut away.

Welding the window frame

The bottom section of the windscreen frame was badly rusted and the easiest solution was just to replace it completely.
The bottom section of the windscreen frame was badly rusted and the easiest solution was just to replace it completely.
Before welding in the piece we cleaned and painted the heater area. It's not easy to do afterwards.
Before welding in the piece we cleaned and painted the heater area. It’s not easy to do afterwards.
The welding jig ensured the correct position.
The welding jig ensured the correct position.
And the window frame welded. Compared to some of the other stuff this was pretty straightforward to do.
And the window frame welded. Compared to some of the other stuff this was pretty straightforward to do.

Bonnet fitting problem

It seems the spare bonnet we had was a little too narrow at the rear.
It seems the spare bonnet we had was a little too narrow at the rear.
We tried to stretch it with a jack, but it seems the Saab 99 bonnet is just too stiff to easily accomplish this. Fortunately it seems I found a better bonnet and need try it later.
We tried to stretch it with a jack, but it seems the Saab 99 bonnet is just too stiff to easily accomplish this. Fortunately it seems I found a better bonnet and need try it later.

Making a bigger hole for the light

Removing some storage rust on the front fender.
Removing some storage rust on the front fender.
Making a bigger hole for the light.
Making a bigger hole for the light.
And the hole done.
And the hole done.

Fitting the fenders

Cutting away some more rust.
Cutting away some more rust.
Fitting replacement pieces.
Fitting replacement pieces.
And fitting the fender.
And fitting the fender.
Fender in welding jig.
Fender in welding jig.
Fitting the right hand side fender.
Fitting the right hand side fender.
Seems like nice fit here.
Seems like nice fit here.
Looks like a bit of a job here.
Looks like a bit of a job here.

3 Comments

  1. Joachim Wanrop
    Reply

    It is nice to see that you making progress. I am impressed. I also started with restoring a 1978 Turbo CC. I can lock at the work you making and take ideas.
    Thanks.
    Regards Joachim

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