Another XR Build Thead. This time with 1000% more Saab

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Doivi Clarkinen

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MattWatson
Planning on pairing down the stock wiring harness,

Yeah, that's loads of fun. Literally half the wiring harness is wires running back and forth all over the car to the center console to tell you if you have a burned out light bulb.

Yep, I had a spare trash bin that I threw all the wiring in... it filled the damn thing. it probably weighs 50lbs. At least the wires are a light gauge so you can look at them and generally tell if it's useless.

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MattWatson

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Doivi Clarkinen

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MattWatson
Planning on pairing down the stock wiring harness,

Yeah, that's loads of fun. Literally half the wiring harness is wires running back and forth all over the car to the center console to tell you if you have a burned out light bulb.

Yep, I had a spare trash bin that I threw all the wiring in... it filled the damn thing. it probably weighs 50lbs. At least the wires are a light gauge so you can look at them and generally tell if it's useless.

Attack of the killer wiring loom:

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

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john vanlandingham

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MattWatson

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Doivi Clarkinen

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MattWatson
Planning on pairing down the stock wiring harness,

Yeah, that's loads of fun. Literally half the wiring harness is wires running back and forth all over the car to the center console to tell you if you have a burned out light bulb.

Yep, I had a spare trash bin that I threw all the wiring in... it filled the damn thing. it probably weighs 50lbs. At least the wires are a light gauge so you can look at them and generally tell if it's useless.

Dave its closer to 2/3 is useless.
Attack of the killer wiring loom:

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

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MattWatson

Quote
Doivi Clarkinen

Quote
MattWatson
Planning on pairing down the stock wiring harness,

Yeah, that's loads of fun. Literally half the wiring harness is wires running back and forth all over the car to the center console to tell you if you have a burned out light bulb.

Yep, I had a spare trash bin that I threw all the wiring in... it filled the damn thing. it probably weighs 50lbs. At least the wires are a light gauge so you can look at them and generally tell if it's useless.

How are you going to tell if a tail light goes out? HOW!?

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MattWatson
Anyone have any advice as to what they wouldn't do again post shell prep? (Well maybe including seam welding, I have some left to do)

I am trying to get my mind back around this beast. Planning on pairing down the stock wiring harness, running stock ECU, or potentially megasquirt has been sitting in a corner for a while.

I could write a book here...
In the active driver Dave Clark's car (not the active builder Dave Clark) formerly owned and built by Sean Medcroft, Sean did a new wiring harness using the stock plugs and paired down. He has started a pin board to replicate it. A pretty please for a second one might move it along a bit. I haven't bothered him on it since I haven't had time to do much on my own car, though it does now have an engine in the engine bay.

For ECU, I picked up the AEM Stinger and engine wiring harness, one of two or three custom units built by Joe Morgan. It has maps from being run on a ~450 whp car with Essy head and Holset and a stock setup so will probably start my car but will need tuning.

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Grant Hughes

Oh yeah, DO NOT let the dust accumulate!
Get it running again first and foremost. Worry about any "upgrades" later.

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Grant Hughes

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Thomas Kimsey
How are you going to tell if a tail light goes out? HOW!?

Like my new (to me) Jeep... Dear god a tires low!?! I would NEVER have known! There is no easy visual way to check things like that!? AND fuck 75$ sensors.

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MattWatson

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Thomas Kimsey
How are you going to tell if a tail light goes out? HOW!?

Like my new (to me) Jeep... Dear god a tires low!?! I would NEVER have known! There is no easy visual way to check things like that!? AND fuck 75$ sensors.

My daily driver complains like hell when the windshield wiper fluid is low. Its idea of low is enough to last a few months...

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MattWatson
Let me know if there is anything you want better pictures of. I'm more than willing to help out.

What gauge did you use for the footwell reinforcements?

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Thomas Kimsey

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MattWatson
Let me know if there is anything you want better pictures of. I'm more than willing to help out.

What gauge did you use for the footwell reinforcements?

16g is fine.. that's 50% thicker than the floor/firewall.

Cardboard template first, cut some slits so it complies as you weld and hammer it. If you have less than size 14 boot side you and pump the floor UP so the heel is better positioned to the pedal and make a false floor.

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

Quote
MattWatson
Like my new (to me) Jeep... Dear god a tires low!?! I would NEVER have known! There is no easy visual way to check things like that!? AND fuck 75$ sensors.

Don't forget the vast majority of car owners today don't have a clue about things like tire pressures or other basic maintenance issues. That said, I picked up a nail in a rental Yukon a few years ago and the pressure sensors saved me from being relatively stranded in the middle of nowhere. (No chance to visually check between picking up the nail and the warning coming on)

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First Rally: 2001
Driver (7), Co-Driver (44)
Drivers (16)
Clerk (10), Official (7), Volunteer (4)
Cars Built (1), Engines Built (0) Cages Built (0)
Last Updated, January 4, 2015

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john vanlandingham
Blame is for idiots. losers.

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john vanlandingham

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Thomas Kimsey

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MattWatson
Let me know if there is anything you want better pictures of. I'm more than willing to help out.

What gauge did you use for the footwell reinforcements?

16g is fine.. that's 50% thicker than the floor/firewall.

Cardboard template first, cut some slits so it complies as you weld and hammer it. If you have less than size 14 boot side you and pump the floor UP so the heel is better positioned to the pedal and make a false floor.

Yep I used 16 or 18 if I remember correctly. No slits were needed on mine, 2 bends and it went in easy. I used cardboard, marked the bends on the steel and underbent them slightly. Leaned on it with my off hand while tacking the thing down. One of the easiest things I had to do on the car lol.

Take the steering column and pedals out. It makes it 1000 times easier. And then you don't hit your head.

I needed a pick me up, since all i've been doing is filling holes and starting some bondo work as well as building a rotisserie, so I decideded to test something before it got too far in.

I was able to finally order a 41mm socket (I refused to pay 40$ for a socket locally, so I ordered one from princess auto, which is almost the same as harbor freight, since they didn't have any in stock) I then whipped out my pilfered copy of the xr4ti manual to find out the spec for the front hub nuts.... 240ft\lbs!! I was worried because after confirming online, most people's torque wrenches dont go that high. Luckily mine did.

Getting 240 ft\lbs on something is not easy. I ended up wedging an 4ft 2x4 between two wheel studs, knelt on the board and then was able to put all my remaining body weight (and I'm not light...) on the torque wrench and JUST get enough.

I guess a couple bearings wern't 100% seated, because it did close up the gap between the hub and upright a bit, but meh, other than being stiff due to new grease, seems fine. I was then able to throw on a disc after going to buy a 9/16 drill bit (I didn't have one for some reason...) and opening up the holes a wee touch.

Then, the moment of truth, will the disc go over the studs? Yep! perfect fit, a tap with a rubber mallet and it seated perfectly! wanting to test my luck, I went and grabbed a caliper, some left over m12 bolts and a set of pads to see if everything was all good.... aaaaaannnndddd it was 100% perfect!







I bow to John, the master machiner! everthing looks great, it is almost exactly centered in the pads (the caliper could move out a half to quarter mm to make it exact, but who cares! Saab guys have run em a 1/4" out without issue)

Now I just need to get the car painted so that I can put everything back on and start plumbing the brakes with all the pretty fittings and stuff I got for christmas...

Whaddya know? It all worked..Who'd a thunkit?

'Bout any ol' wheel will fit.

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

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john vanlandingham
Whaddya know? It all worked..Who'd a thunkit?

'Bout any ol' wheel will fit.

I hope so since I have 14 of them sitting in the garage. Hope the minilites clear, some people have had to relieve them on the back side. I wasn't that ambitious today haha.