119 replies to this topic

[leet5r]

outstanding bud , lookin like a serious motor now with that spec , wouldnt mine 1 of these myself now

[T5frankie]

what and your cossie? lol

[bonelorry]

Small update

I couldnt be happier with the car, Not one problem since doing the Engine/Gearbox conversion 2 weeks ago. Its not used a drop of Oil/Water and i am averaging 26 MPG which is only 1MPG less the 2.0 but it so much nicer to drive IMO. Loads of bottom end it just pulls from 1500RPM and keeps pulling...You just dont need to rev it anymore. Quite deceptive in terms of how quickly it builds up speed now.

Since buying the car 6 months ago ive always fancied changing the wheels but IMO not many aftermarket alloys suit the 9-3 Viggen/Aero so there was only ever 2 or 3 options i wanted to go for, One was Compomotive MO 6 in Anthracite but these are very expensive to buy new and from past experience the quality of the finish can be hit and miss with Compomotive. The second was a similarly styled wheel Revolution Millenium in Anthracite, These would have been made from cast blanks to my spec and worked out a bit cheaper than the Compomotive and these where more than likley what i was going to opt for. Quite to my surprise i was offered a set of very rare 17" Hirsch Performance alloys and even though it was only a few days after fitting the engine they where the right money Cheap so i bought them  

They are quite corroded and need a refurb but i want to get them refinished in dark Grey or Anthracite anyway and have the front Grille done at the same time, Ill be able to sell my Double Y's and recoup a few £££ so it shouldnt cost me too much overall.

I spotted this picture a while back, Its on an American Viggen but it just looks so right and its given me inspiration with the Hirsch wheels and what my car should look like once i fit mine in a similar colour...

[Muhammad]

Can we swap cars?

[bonelorry]

Muhammad, on 12 February 2012 - 21:47 , said:

Can we swap cars?

Mine wouldnt be fast enough for you....Yet!

[stedman]

bonelorry, on 12 February 2012 - 21:56 , said:

Mine wouldnt be fast enough for you....Yet!

Yeah but when you got it back it would be uber quick!

[Raj]

I like these, i drove one once with a few mods, not got a clue what, but it was quick... oversteered like a bitch but was nice to drive....

Looking very sweet dude

[bonelorry]

stedman, on 13 February 2012 - 00:52 , said:

Yeah but when you got it back it would be uber quick!

It will be when ive done, I am aiming to be in the 4 to 5 second 60-100mph club.

These Saab engines and the later T7 engine managment on my car love V-power & Tetrosyl Thinners (Which is roughly 20%-30% toluene, about the same xylene (injector cleaner) and the rest is methanol) OR loopy juice as the boys call it, Adding a ratio of 1:10 so thats 10% of the fuel in the tank Enables you to pull back the boost and add some ignition advance but make more power/torque.

Edited by bonelorry, 13 February 2012 - 07:20 .

[leet5r]

nice rims m8 , a do like the comp also and have been thinkin about some for the cosworth , but the new comodoras or how ever they are prononced

[bonelorry]

Did my first timed 60-100mph run tonight (on private land ofcourse)



I did it in 4th gear and i didnt actually put my foot down until i was at 60mph as you can see by watching the boost gauge on the roght so it could possibly be a bit quicker had i have started from 40mph, Ill do a 3rd gear run at some point soon.

Not too bad for stage 1 IMO which is 270bhp/400NM Quicker on my stopwatch than my old 850R which i used 3rd gear for!

Edited by bonelorry, 16 February 2012 - 22:34 .

[bonelorry]

All is still going well with the car, Now 1 month in and 500 miles covered with the new motor fitted and not a single issue  

Although i wash the car thoroughly weekly its not had a proper clean for quite a few months now due to the weather and doing all the other work on the car in my spare time so since the weather was good and i had some spare time i had a 6 hour cleaning/detailing session on the car today....

Rinsed the car and wheel arches thoroughly
Washed the car using 2 bucket method with a Lambswool mitt and Meguires ultimate shampoo
Washed the wheels, Tyres and wheel arches using a Meguires Microfibre Mitt, Soft wheel brush and bottle container with foaming head containing Stardrops soap to a high concentrate
Rinsed the car again
Clayed the whole car including glass with a Meguires Clay kit using Meguires NXT Gen Quick Detailer as lubricant (Did this last week)
Rinsed the car again
Dryed the whole car with one new Autoglym Chamois, Dryed the wheels, Door shuts and engine bay with older Autoglym Chamois.
Cleaned the glass with Autoglym fast glass then Autoglym Glass Polish (Did this last week)
Removed any tar specs using Autoglym Intensive Tar remover
Polished the car using Autoglym Super Resin Polish using a sponge applicator to apply and micrfibre towel to remove
Waxed the car twice using Collinites No:845 liquid insulator was using same application and removal technique as with polishing
Dressed the tyres, Bump strips and other plastics/textured parts with Meguires Endurance Tyre Gel
Cleaned the Interior of the car and used Autoglym Leather Care on the seats

Thanks to Willhouse for taking the snaps...


Detailed Aero by outHOUSEpics, on Flickr


Detailed Aero Back by outHOUSEpics, on Flickr


Aero Engine by outHOUSEpics, on Flickr

[bonelorry]

Right after much thought and countless hours researching i have decided that im not going down the TD05 turbo route, I have no doubt that it would have made the desired power on my engine and would work out much cheaper in the long run than say a Garrett alternative but i think the TD05 would be much better suited to a revvier 2.0 application purely from a drivabilty point of view.

From scouring the MLR forum i read that all the Evo owners who run the stock framed TD05HR-16G-10.5T and have 2.3 stroker motors say the same thing...The car drives like a modern Turbo Diesel, On the 2.3 stroker the turbo has done its business by 5000RPM and even though its a bit more responsive than on the 2.0 you will tire of it very quickly.

My good friend Rich B.R.D who has helped me massively throughout the build runs the same TD05 on his car and has the same 2.3 engine spec as mine, Since his car is a stripped out weekend toy/thrasher and only weighs 1000KG its very responsive but he openly admits he wouldnt want the TD05 on his 9-5 Aero as its just too laggy and would spoil the car to drive. Also shadowing what the MLR Evo owners say the power does indeed drop off at 5000RPM.

I have looked at all options with going the TD05 route especially focussing on quicker spool....

Titanium/Alloy wheeled units although spool quicker dont last as long as the stock Iconel/Alloy wheeled units if ran at higher than stock boost levels so that ruled out going down that route.
BB cored converted Iconel/Alloy wheeled TD05 units are expensive which defeats the object of going down this route.
I could possibly experiment with some hotter camshafts to extend the power beyond 5000RPM on a TD05 but that would jepordise bottom end response and drivability which is not the route i want to go down and then the cost goes up massively also.

Thinking about it all id much rather have a very flexible and usable 350ish BHP and similar torque with little lag than a 400BHP car thats not as drivable just for the sake of it. Ive spent alot of time on the car and im currently enjoying it alot with the stock turbo, Obviously i want more power and could go daft if i wanted to but its not why i built the car!

I know the cost is going to go up but i want the make sure i make the right choice as fitting the wrong turbo would ruin the car, Given the above and the fact the TD05 is not exactly a straight forward fit im thinking along the lines of....

SaabFlight TD04 Hybrid, Supposed to be an awesome unit although not many people have this turbo. Its based around the 9000 Aero TD04 frame with 6cm2 housing so would have to be clocked to go on my 9-3 but thats no problem. Nothing like a 19T as it uses Garrett GT28RS internals and both the Garrett wheels and TD04 casings are altered to suit and possibly but i dont know for sure a BB core?? Supposed to do 380BHP on a 2.3 so SaabFlight claim although i reckon 350BHP is realistic with 350-380LB/FT going on 9k Aero figures. Pretty much as bolt on as you can get as i could retain my current 3" Downpipe etc Apparently a very responsive unit with virtually no lag. Pricey unit and i would have to supply a TD04 but sounds like the perfect turbo?

Garrett GT28RS, Tried and tested unit been around for years, The bigger A/R version which will do 350-370BHP on a 2.3 and works best with the T5 camshafts if im correct? Faero will confirm this im sure. BB cored so will be responsive and be a nice drivable/usable unit. Fits stock T25 flange on Saab manifold but will require oil/water lines making up and a 3" V-Band fabbing into my current D/P using a 5 bolt to 3" V-Band adaptor on the hotside. Can be had second hand so might not be too expensive in the long run?

Or am i wasting my time going down the Garrett route when SaabFlight make the hybrid which is going to do the same thing?

Any input would be gladly recieved chaps.

[mitchyboy01]

Hi mate, awesome build and I am loving the attention to detail. I think you right in not going for all out power and going for a balance of power and drivability. I'm not sure on the price of the SaabFlight unit bit if it doesn't need downpipe mods you have saved a few quid and a bit of hassle already over the GT28RS. I wish I had started with a Saab now and not my S40. It looks spot on and I like the thought of forged internals as standard too!!

[bonelorry]

Its been an expensive month but the Saab is now wearing its new wheels  8)

Hirsch Performance 6 spokes which are 17" x 7.8J ET42 fitment, These are the earlier design castings but are now a one off set that have been shotblasted to remove any corrosion, Had all the Hirsch emblems professionally filled/smoothed and are painted Porsche GT3 metallic Grey with black centre caps.

I have also had the front Grille painted Gloss Black and the mesh Matt Black but im undecided about this at the moment so no pics of that  :?


New Wheels by outHOUSEpics, on Flickr


Big Hirsch Small Hirsch by outHOUSEpics, on Flickr

Regards Simon

Edited by bonelorry, 24 March 2012 - 19:41 .

[julek780]

Hi Simon,  Aero looks great, i think the performance from the engine transplant has transformed the low down power, i have an Aero and have replaced my alloys with Viggen wheels to change the look. I still have the 2.0 engine and hope to get a stage 3 remap from Karl next weekend at the mmm .I would love a viggen, but may go down the same route as you with an engine transplant. Do you need to use the Viggen gearbox , or can you still keep the 2.0 standard gearbox for now?
Regards Julian

[bonelorry]

julek780, on 24 March 2012 - 20:05 , said:

Hi Simon,  Aero looks great, i think the performance from the engine transplant has transformed the low down power, i have an Aero and have replaced my alloys with Viggen wheels to change the look. I still have the 2.0 engine and hope to get a stage 3 remap from Karl next weekend at the mmm .I would love a viggen, but may go down the same route as you with an engine transplant. Do you need to use the Viggen gearbox , or can you still keep the 2.0 standard gearbox for now?
Regards Julian

Hello Julian,

Thank you for your kind words, Im guessing you mean SaabNoob/Karl is doing your stage 3 software? Ifso he is very good indeed!

The Viggen spec gearbox is not required, Even if you go to 2.3 and build a hybrid engine like mine your exisitng gearbox and drivehsafts will work fine, I went about it all the hard way as i was offered and bought a Reconditioned 9-5 Aero gearbox already fitted with a Quaife LSD for the right money so had to get it.

Since the 9-5 Aero gearset and Diff is the same as the Viggen but the 9-5 Gearbox casing is different we built a hybrid gearbox and swapped all the 9-5 internals into a 9-3 gearbox casing thus making a Viggen spec box plus LSD, If that wasnt hard enough i had to then track down some Viggen driveshafts and Viggen Intermediate shaft both of which are extremley hard to get a hold of these days since they only produced a limited amount of Viggens.

Just to note the actual gearset is the same in the normal box and the Viggen box, Its the differential thats much bigger in the Viggen/9-5 Aero box's and this is why the Driveshafts/Halfshaft are also different.

Let me know if you need any help/Advice when you decide to build an engine, Since yours a T7 you will need various different parts from different cars to built a Hybrid motor

Have a good one at the MMM meeting, I cannot make that one due to work.

Cheers Simon

Edited by bonelorry, 25 March 2012 - 09:30 .

[bonelorry]

Small update...

All is still going well with the car, I am now 1500 miles and 3 months in on the new motor with no issues whatsoever Its used no oil or water and im averaging 28mpg according to the SID which im chuffed about.

Ive been after buying an uprated rear anti roll bar for the 9-3 but frustratingly seem to be having little luck, Parts for Saabs have a 3-4 week wait on the SAS item. Abbott Racing dont have any on the shelf and would have to have one made so ive just sent an E-mail to NickT in the states about shipping one of his over for me fingers crossed.

After fitting the 2.3 ive looked at lots of options ref bigger turbo's, Weighed up the pro's/Con's of each one and have changed my mind many times, I still cannot decide what to do turbo wise and the more time is going on im beginning to wonder if theres much point in going over 300bhp anymore?
Over the last week its the first time ive done quite a few spirited miles in the car since fitting the engine and LSD, Once over the Woodhead pass and had a great drive through Derbshire at the weekend on my way too and from the UKS camping weekend. As the car currently is its just so flexible with the 2.3, Response is almost instant with the stock TD04 and i really enjoyed it as a package and actually fealt quite satisfied with how the project has progressed and the transformation of the car compared to how it was when i bought it last September.

When we originally put the Stage 1 software on the car we knew it was not 100% and a month or so back we did some live logging runs on the road to see if everything was working right before we went any further tuning wise with the car. After a couple of runs it became obvious that at WOT the Requested Airmass of 1270 was not been met, The boost was building and just about making the Request but was then rapidly dropping off through the midrange and expectably up the higher RPM's. As the boost was dropping the duty cycle on the APC valve was going up but had no effect, When we fitted the engine i replaced the turbo and we set the base boost using a Mitivac so know thats ok. The result is that the actuator spring is too weak and is bleeding off too much either a helper spring OR an uprated actuator would be required before i could go any further or even make full stage 1 power.

Since at that point i was looking at uprating the turbo and i was happy with the cars performance i wasnt too concerned about the bit of missing boost so never went any further, Since im now undecided on what to do i wreckon im going to keep the stock TD04 and go for a Stage 3/4 map and max out the stock TD04.

So i bought a new Forge Actuator last week off Meatfeast "Many thanks" It comes with the original Green spring which equates to the stock base boost and the stiffer Yellow spring...



Ive also had this 3.5 Bar Fuel pressure regulator sat on my bedroom floor for quite a few months now...



With these fitted i wont loose any bottom end drivability but will hopefully achieve 290-300bhp & 320LB/FT, At this point i will have to see how i feel about the performance and review my options.
Regards Simon

[V70D5]

Fookin hell!

Just had a scan of your project and am mighty impressed.  Fair play to you for it.  I'm not a Saab fan but that is very, very nice indeed.   Keep up the fantastic work.

[bonelorry]

V70D5, on 17 April 2012 - 21:18 , said:

Fookin hell!

Just had a scan of your project and am mighty impressed.  Fair play to you for it.  I'm not a Saab fan but that is very, very nice indeed.   Keep up the fantastic work.

Thanks Ben, Its come on along way and has taken alot of my time, Money and patience and its not finished yet LOL. Not far to go with it now though!

Cheers Simon

[bonelorry]

Might be thinking about selling this soon, Not going into my reasons but ill have to see how things go over the next month or so.

Cheers Simon