My second 480...... project 'sleeper'

Here you can start a thread about your 480 days. Only the starter of the thread is allowed to fill his thread, and only one thread per person. Threads are simply a personal diary.

Moderators: jifflemon, coyote1980, Rachel

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

My second 480...... project 'sleeper'

Post by Ade » Sun Oct 30, 2016 12:51 am

So, after almost 5 years of owning and loving my first and only, tatty and tired, but ever faithful 480 turbo, the chance has arisen to get my hands on a lovely looking #almost# rust free, largely resprayed and very tidy, lowered black turbo :hopping: Awesome looking car.

There is one small catch however............ It will not have it's engine, gearbox, loom or ECU's. Unfortunately it is donating said items to a Renault 5 GT Turbo, which, in my opinion as a great 480 lover, is absolute bloody sacrilege, but each to his own, right? I'm glad the car was offered in one piece as a rolling shell rather than being dismantled and so I thought I'd rescue it and try and give it a new lease of life.

So once the engine has been removed and I go and collect it, I will have somewhat of a blank canvas to work with. My initial thought was a straight swap of running gear from my existing car, however, for one, I'm quite attached to 'old faithful' and don't really want to take her to bits and secondly, the idea of doing something a bit more interesting with the black one has been steadily growing in appeal.

My plan, therefore, is to attempt a conversion to a 2.0 turbo Saab engine. Early 9-3's are available for the right money as a donor car and the engine produces 185hp in stock form (never mind the masses of tuning potential that these bulletproof lumps have) which should make for quite an entertaining 480, given that the 480 weighs in at around 500kg less than the Saab, the latter not exactly being a slow car to begin with. :D

I'm not aware that anything quite like this has been done, at least not a Saab engine and I think the concept has real potential to make a seriously fast, yet reliable and civilised, ultimate 480 'sleeper'. I do not underestimate the enormity of the task that lies ahead, it will be a far cry from the 'bolt together' scenario with the Volvo engines going into Renaults and will require a lot of engineering- mounts, driveshafts, gear linkage and conversion to a hydraulic clutch system being the items that stand out initially as key aspects of the project to get right, but then of course, the Saab head is crossflow so exhaust will have to be sorted as well, not to mention the fact that the engine bay might need some 'adjustment' (cue the angle grinder :eek: ), maybe some stiffening, and the list could go on and on............ wiring, plumbing......... I can see plenty of :wall: :wall: :badmood: :badmood: :cry: :cry: moments ahead!

This said, I am determined to make this happen, I have always loved Saabs and currently own a 9000 Carlsson, the car that has led to my love of Saab engines. I've got a feeling that a 480 with a Saab turbo engine could be a really nice combination and now I have the perfect opportunity to make it happen and save a nice example of a 480 turbo and make it unique in the process.

This won't be happening over night, I haven't taken delivery of the rolling shell yet, nor bought a donor Saab. I will have the 480 shell by the end of the month and plan to buy a saab this side of xmas but I wont really get going on the project until the new year. Realistically I think my timeframe to get this car on the road will be around 12 months from now. In the meantime I'm going to do some cleaning up and sealing and a little welding on the underside of the shell and prepare it for its transplant up front which will probably amount to a more or less total stripout of everything except steering, suspension and brakes. Thinking of brakes, if the project succeeds, brakes may very well be the next thing on the list for an upgrade! Once the 480 has a clear and empty bay, the prospective Saab can come to bits and the swearing and cutting of things can begin as the engine inevitably struggles to fit in the hole provided by the volvo!

I've started this thread to keep a record of my thoughts throughout the course of this undertaking as I thought a few of you 480 nuts out there might find this an interesting project and if any of you are into saabs as well I'd welcome any thoughts you might have about it.

Wish me luck :D I do hope it fits......
O.C. 480 D.

Martin Mc
Can tell where the 480 was built
Posts: 369
Joined: Tue May 29, 2012 11:57 am

Re: My second 480...... project 'sleeper'

Post by Martin Mc » Sun Oct 30, 2016 11:10 am

Hello Ade,

What a great idea and a brilliant opportunity to have a go! I used to have a 9000 2.3 full turbo which, even with 160K plus miles on it, went like the proverbial clappers. The thought of that kind of power in such a relatively small bodyshell is mind-blowing in potential. I guess you'd need to uprate the brakes!!

This sounds like a wonderful drip-feed project for us all to tune in to from time to time, so I'd definitely welcome pics from day 1 - delivery of your rolling shell.

Looking forward to seeing this take shape! Best of luck!

Martin
Volvo 480 - There's NOTHING like it!
Previous 480 pedigree: 1992 ES (1.7 White) 1993 ES (2.0 Red) 1994 S (1.7 White) 1994 ES 2.0 (metallic red) 1995 S (1.7 Black) 1993 ES (2.0 Paris Blue) (0ver to you Keith!) #467/480 Celebration (flame red metallic)
Every decent bloke deserves an extra-marital car (so my wife tells me)(apparently it keeps me out of mischief.... really..)

Alan 480
480 Is my middle name
Posts: 1222
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: My second 480...... project 'sleeper'

Post by Alan 480 » Sun Oct 30, 2016 7:51 pm

would a 5 pot volvo ex T5 fit? :hopping: just maybe some common parts tween the 480 & drive train
now that would be wild!

I did see that 'shell' for sale and assumed that teh engine had gone into a renault 5 :cryhard:

but if you got the chance to save a 480, crack on, do let us all know progress (even if slow)
Alan

480 ES 2litre x 2 (1 x Normal, 1 x 'Celebration' ? ), C30 1.8ES, SS1

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Mon Oct 31, 2016 6:59 pm

Martin - Yes, of course I will post pics as well as writing up about the various stages of the build. There is only one problem- I never have worked out how to post a picture on this forum! If someone could enlighten me I would be most grateful as I'm sure people will be keen to see pictures of this beast taking shape! As for Saab engines, I'm totally with you on the high mileage thing, my 9000 Carlsson (which is a 2.0T but heavily factory modified for the 'Carlsson' edition) has done over 200,000 and still flies like sh#t off a well oiled shovel! This is why I'm so keen to build a Saab powered 480, massive performance potential with bulletproof reliability. I want it to be fast every day, not just the days when it's not broken! Plus, there's just something really sweet about Saab turbo's, dunno what it is but I just love everything about them from the noise they make to the way they deliver the power. In my mind, it's the sort of engine the 480 should have had in the first place.

Alan - T5 crossed my mind but I didn't pick the T5 lump for a number of reasons:

1. Cost. An 850/V70 T5 fetches a hell of a lot more than a late 90's Saab 9-3 turbo. Spares/repairs 9-3's go for next to nothing and the engines are not generally the reason for the car going cheap. Plus, there's always plenty of them about. Here's a 'for instance'- a 2.0t convertible with a roof problem (common) generally fetches less than £300.
2. Size. A T5 engine is a behemoth of a thing compared to the 4 cyl Saab engine and so I'm much more confident that the Saab lump will fit with less, if any cutting in the engine bay whereas I'm not so sure the T5 would go at all.
3. You mention commonality of drivetrain parts, I don't know for sure but I guess since the T5 was nothing to do with Renault, it would require just as much customisation and engineering as any other conversion.
4. Realistically, the Saab engine is capable of just as much power as a T5 as far as what would be reasonably safe, driveable and practicable in something like a 480 chassis. In fact, I would say the Saab could go further without internal modification than the T5. The T5 is an aluminium block with wet liners which are prone to move around causing major issues when producing big power. Saab is a good old iron block and they have been known to do 3-400hp on standard, unmodified internals. When I say these engines are bulletproof, I do mean bulletproof. Some years ago I had a n/a 2.0i 9000 CSE and I mis shifted into 2nd rather than 4th at about 90mph. The engine survived without any issue at all. This would have blown most engines to pieces. Need I say more?
5. Finally, I'm not 100% sure about this as the mountings might be different in the 9-3 as opposed to the 9000 but, from looking at the mountings in my Carlsson (which is fundamentally the same engine, B202) it seems that the basic layout of the mounts is not massively different to the 480. Two at the front, one each side to subframe ahead of lower arm mountings and a central(ish) one at the rear. The 9000 also has a torque mount from the head to the suspension strut area whereas the 480 doesn't, however, the fact that the main 3 mounts are arranged in basically the same layout should make life a lot easier.
O.C. 480 D.

Alan 480
480 Is my middle name
Posts: 1222
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: My second 480...... project 'sleeper'

Post by Alan 480 » Mon Oct 31, 2016 7:13 pm

Ade
having the two cars side-by-side is often a bonus, you can do some 'measuring' and design BEFORE head to scrap yard.
and as you say the T5 does command a premium, £300 for a whole SAAB car can't be bad. If you know your way around the SAAB even better, whats not to like?

PS there SHOULD be a 'torque' strut, OK a shock absorber (a weedy wee thing) on the 480? and I guess a more rigid mount will not do any harm . . . . .

only issue might be the brake servo is 'tucked-in' quite tight behind block . . .but if the donor is non ABS , plenty of room for a remote servo at N/S or even the round tube across the bulkhead like the early FWD Escorts (or similar), I think it was those?

and I have NO idea how to post photos, I don't have flikr account or similar, just me own phots on PC :wink:
Alan

480 ES 2litre x 2 (1 x Normal, 1 x 'Celebration' ? ), C30 1.8ES, SS1

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Mon Oct 31, 2016 7:42 pm

I know about 'weedy wee thing' on the side of the engine in the 480, the mount on the Saab is quite a way different to that but I don't see this as the biggest hurdle, not by a long way!

It was having the Carlsson and comparing engine bays that initially got me thinking about the possibility of a saab powered 480, and you are quite right in saying that it is a good opportunity to start coming up with some concepts and eyeing stuff up and measuring things. Without a doubt, this will be a valuable and sensible exercise.

As for brake servo, my rolling shell 480 is the same as my daily driver turbo and both have the accumulator type servo which is located on the gearbox side, so plenty of room there, good point to mention though, I forgot some 480's have the vac servo over the other side. I've just had a vision of my ex girlfriends 480 ES engine bay, and you are quite right that there is no way you'd get the Saab lump in there without moving it!

In terms of moving stuff around in the 480 bay to make room, one thing I think will definitely have to be rearranged is the cooling fan and radiator/intercooler assemblies as the Saab head is a pent roof chamber, cross flow design with the turbo up front (which is great but it does make the whole deal a bit bigger in terms of the 'depth' required in the bay). I think getting enough clearance around the turbo will be one of the major headaches to contend with. I can foresee having to use a shorter rad and intercooler mounted much further forward and then cutting some of the bulkhead away. Alternatively, if this is indeed a problem, it might be that the scuttle could be modified and the inlet manifold could sit somewhere a bit nearer the wiper motor, hence giving more room around the front for the turbo. This could be preferable in terms of weight distribution as well, to have the engine as far back as possible. I don't want it to understeer like a 1980's Audi! The problem with those things was that the engines were simply too far forward and one of the greatest charms about the 480 is its superb handling so I need to be careful not to bollocks it up!

All food for thought eh? :D
O.C. 480 D.

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Mon Oct 31, 2016 7:45 pm

all this is pure speculation of course, I'll only really know once I offer it up in due course. Which I will of course post a picture of if only someone would tell me how! :lol:
O.C. 480 D.

Alan 480
480 Is my middle name
Posts: 1222
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: My second 480...... project 'sleeper'

Post by Alan 480 » Tue Nov 01, 2016 4:56 pm

ref rad location, plenty of room 'up front' to move rad around and on mine it doesn't extend full width inside the cooling intake so a shallower one FULL width could go nearer front bumper , even at a slope if reqd to keep top forrad for room for turbo, or even a pair of smaller ones with the turbo sitting / poking between them? The slam panel doesn't do an awful lot except keep bonnet closed which you could do with a pair of catches next to head-lamps so freeing up that whole area?

I assume that the exhaust runs under the sump/clutch area on the SAAB?

cutting into main bulkhead between engine and interior is a major job, it's OK on Scimitars where it's GRP :wink:
Alan

480 ES 2litre x 2 (1 x Normal, 1 x 'Celebration' ? ), C30 1.8ES, SS1

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Wed Nov 02, 2016 9:10 pm

Image
O.C. 480 D.

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Wed Nov 02, 2016 9:11 pm

Image
O.C. 480 D.

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Wed Nov 02, 2016 9:17 pm

figured out pictures at last :D

So, there it is as I viewed it. Still has its engine and box in this photo and as I understand it they are being removed over the next few days. Next pictures will be of it on the trailer on its way back to its new home, most likely towards the end of the month.

Alan - Hear what you say about radiators and there being plenty of room up front, I think it's all this space at the front that will make this possible, and you're quite right, the exhaust on the saab drops down underneath the sump.
O.C. 480 D.

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Fri Nov 04, 2016 1:27 pm

Quick update, firstly, in the interests of keeping technical information accurate, contrary to what I said in a previous post, the donor 9-3 will be providing a B204 engine, not a B202, the main difference being that the 4 rather than the 2 at the end indicates that the engine has 4 auxiliary shafts, not 2. ie the B202 has 2 camshafts and that's it, the B204 has two cams and also 2 balance shafts to make it run smoother so a total of 4 auxiliary shafts.

I've also been doing some research on the wiring for this engine and it seems that the B204 is quite a popular choice for various engine conversions (especially :kill: Vauxhalls, as the later GM era Saabs share an almost identical subframe to Astras etc. making it a nice convenient 'bolt together' choice, a bit like those Renault gits that like taking 480's apart! :lol: ) Luckily, the B204 is an evolution of a 'proper' Saab engine (the B202 found in my 9000 Carlsson) and not a pile of GM rubbish as would be found in even newer Saabs. Point being, it's an engine that is routinely transplanted into places that it wasn't designed to go and there's good knowledge out there about getting it running right in non original applications. I've signed up to the UKSaabs forum in the hope that this project will generate some interest in the Saab community as well and I'll be able to pick some expert brains as regards sorting the electrics out. If they're willing to help people do something as depraved as butchering a Saab for the sake of a Vauxhall (which there's plenty of threads about on UKSaabs), then hopefully my project should be quite warmly received! I think a 480 is much more deserving of an engine like this than a bloody astra. It's also good news from the point of view that if the B204 will fit in an astra, getting it into a 480 shouldn't be too difficult! :? I hope............

Oh and lastly, it has become apparent that the 'Trionic 5' ECU which will be running the Saab engine is very easy to tune, a simple remap should put me in the ball park of 250hp and if I do something with the exhaust and intake, the power should be able to approach 300+hp, again just with simple remapping. I cannot begin to imagine what a 300hp 480 would be like but I'd say 'M power' BMW's and Porsche 911's and the like, be afraid, be very afraid :) It's a good job you can get an LSD for the Saab gearbox, that's all I'm saying!
O.C. 480 D.

Alan 480
480 Is my middle name
Posts: 1222
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: My second 480...... project 'sleeper'

Post by Alan 480 » Fri Nov 04, 2016 5:01 pm

Ade wrote: If they're willing to help people do something as depraved as butchering a Saab for the sake of a Vauxhall (which there's plenty of threads about on UKSaabs), then hopefully my project should be quite warmly received! I think a 480 is much more deserving of an engine like this than a bloody astra.
well at least it's sort of 'Scandanavian' ? :-)

Ade wrote: It's a good job you can get an LSD for the Saab gearbox, that's all I'm saying!
m m m m m torque steer anyone? :hopping:
Alan

480 ES 2litre x 2 (1 x Normal, 1 x 'Celebration' ? ), C30 1.8ES, SS1

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Sun Nov 27, 2016 9:04 pm

So it begins......

Set off for devon with the trailer at 4am yesterday morning to go and rescue my beautiful new 480. It was a very long day (about 500 miles round trip, which is enough when you're towing!) but I finally got the car back to the workshop late last night.

Image

On the north devon link road after leaving barnstaple, final check before hitting the M5


Image

and finally back at the shop
O.C. 480 D.

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Sun Nov 27, 2016 9:36 pm

Couldn't resist going up there today for a bit to make a start. Got the front end stripped out now and tidied up some of the control cables and wiring.

Image
This is how it looked when I picked it up


Image
Image
Image
After an hour or so, lights are stowed safely in the boot!


There's a few more bits to come out of it like the old engine mounts (for now at least, I may or may not be able to make use of them in some way), the driveshafts, the PAS pump and I'm going to try and get my head around the wiring while tidying it up and trying to get it ready for a new installation.

Got a bad feeling about the heater matrix, expansion tank looks to have radweld residue and there's something about the remains of the heater hoses that make me think it may have been bypassed at some point. This has made me think I should take the dash out so I can fit a new one and having the dash out might be the best way to get to grips with the wiring for the conversion if it to be a seamless job. In the grand scheme of this project I guess this is a small setback so I'm not too worried. I'm thinking also that I may strip the front end of the car completely so the engine bay and subframe can be painted. Lots of cleaning and tidying up to do and then to start shopping for a saab to take to bits....
O.C. 480 D.

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Thu Jan 12, 2017 7:41 pm

We now have the Saab :hopping:

Quite an animal it is too! Got me an unlocked ECU, so no immo to worry about and it also has a stg2 tune, so around 250bhp and enough torque to move a small mountain! I can now say with absolute certainty (having driven it with this ECU) that this engine will be INSANE in a 480! The 9-3 convertible is not a light car by any means and by god does it go! Much, much faster than the 480 turbo, and that's with it lugging about an extra 4-500kg.

I'm actually driving about in it at the moment, the daily 480's getting a rest! Thought I'd get some enjoyment out of it before taking it to pieces, plus it gives me a chance to get to know it first, make sure it's reliable etc.

It's had a full service, all the usual, when it does come out it will probably be benefitting from new chains and guides and a new clutch/slave before being recommissioned in the 480.

Although the plan is still a go, I have changed my mind about one thing and that is which 480 it's going in....

The black one I got my hands on is so nice that I think I will be doing a straight engine/box/loom/ecu swap so I have a nice standard 480 to drive while the project is underway and I'm gonna go ahead and try and get the B204 in my blue one as I can do some restoration work on the body/chassis and repaint it while all the conversion work is happening , so that's the 'warmup' job! Should be a cinch compared to the conversion! I'll try and take some pictures along the way and post a 'how to' manual if anyone would find this useful, I guess a complete engine, box and wiring transplant would be a good thing to have covered in the 'how to' section for people maybe lacking a little confidence to try it and I guess it's something that might be happening more and more often now as rust eats away at cars with good running gear.

All this sounds great, and on the whole, it is, but there is going to be a major potential stumbling block that I alluded to in earlier posts and that is the width of the B204+gearbox. Although I have subsequently discovered that it is narrower than the running gear in my 9K Carlsson, which I measured initially (the B204 was made shorter than the B202 as the NG900 and OG93 are narrower than a 9K and was also fitted with a slightly shorter gearbox than it's B202 predecessor), it is still a fraction too wide to drop straight down between the chassis legs in the 480 bay :badmood: Clearance around the subframe could also be VERY tight, if not non existent....

This means that if the end of the box doesn't tuck under the chassis leg (which it may or may not but based on my luck, or lack thereof, I bet you it won't!) there is going to be some serious modding to the 480 required :?

Of course, this is still speculative in that I haven't actually got the B204+box on the crane and attempted to offer it in yet but I have been measuring stuff as accurately as possible with it all still bolted into the 9-3 and so I am a little better informed but only time will tell. One thing is for sure though, a B204 NEEDS to be fitted to a 480, whatever the cost (and I don't mean £££, I'm talking literal blood, sweat and tears!)! The power is hardcore even at a modest stg2, not to mention the fact that it is a really nice, reliable engine capable of massive mileages even when running 300+hp. There's also massive support out there for the management in question, trionic 5.5 so no worries getting parts and tuning support, which is good and more than can be said for a LH2.2 equipped B18FT! Obviously there are countless more trionic managed B204's out there than there are B18FT's left.

One last point of interest for you tuners out there..... the B202 (as found in early 9K's and classic 900's was equipped with LH2.2, just like our 480 turbo's and it is possible (and has been done) to retrofit trionic management to an LH equipped engine, the beauty of this of course being that trionic has writable flash, which can be done with the excellent open source T5 suite via canbus (once the ECU is unlocked with DOS via a BDM interface), and so the tuning possibilities are endless. All parameters in trionic can be changed to suit different sensors etc, it can effectively be used as standalone management, which is why, of course, tuners love it so much! The fact that it has already been done on LH Saabs might inspire someone to give it a go. I would love to but I think I have enough on my plate at the moment! Maybe one day....

Anyway, thanks for reading and hopefully the next update won't be too far away but expect to see a 'how to' engine swap first! I'll be tackling the removal of the engine, box and loom from my blue one on saturday so I can start looking towards getting the black one on the road, then I can ditch the Saab as my daily runabout and start taking it to bits!

Fare ye well fellow 480'ers and have fun in 'em :D Until next time....
O.C. 480 D.

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Thu Jan 12, 2017 8:24 pm

Image

Giving her a service and fresh gear oil (pictured!) EDIT- maybe not pictured, half my photo has been chopped!?!?!
O.C. 480 D.

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Thu Jan 12, 2017 8:25 pm

Image
O.C. 480 D.

Alan 480
480 Is my middle name
Posts: 1222
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: My second 480...... project 'sleeper'

Post by Alan 480 » Fri Jan 13, 2017 5:37 pm

Is the SAAB not too nice to break? . . . . . . .
Alan

480 ES 2litre x 2 (1 x Normal, 1 x 'Celebration' ? ), C30 1.8ES, SS1

Ade
Can tell where the 480 was built
Posts: 337
Joined: Tue Feb 28, 2012 3:25 pm
Location: Northants

Re: My second 480...... project 'sleeper'

Post by Ade » Fri Jan 13, 2017 8:33 pm

I've been having this internal struggle between the Saab loving and Volvo loving sides of my brain :dispute:

The Saab is a real nice car but at the end of the day, it wasn't a lot of £££, £500 to be exact, which was a bargain.

I had thought about taking it apart 'sympathetically', shall we say with a view to rebuilding it from a rough looking, hopefully even cheaper donor.

The other way I'm looking at it is that really, it's a dressed up Cavalier and doesn't tickle my fancy as much as the true Saabs and I have the 9K Carlsson, which is a 'proper', hardcore Saab turbo beast and the money I could get from breaking this 9-3 could go some way to restoring the Carly.

Yet another possibility is to do all the mock up work, manufacturing and fabrication for the conversion, put the 9-3 back together and then get another donor down the line a bit for the actual conversion. Whatever happens I want to take the 9-3 to bits as if I do decide to keep it, I'd like to have the engine out to strengthen the bulkhead (the rack on these is bulkhead mounted and they are notorious for cracking bulkheads) anyway and as I said, I could use it to mock everything up then get a rough, really cheap donor at some point and then it would simply be a matter of fitting everything, all the engineering would be done.

I'm keeping my options open but first priority is to get the black 480 on the road, then I can strip the Saab and go from there. It wouldn't hurt for the engine to have chains and guides at 145k anyway and this is an engine out job whether you like or or not so even if I do rebuild the Saab, having the engine out is the perfect opportunity for a mockup in the 480 and then I can decide what to do. One thing is certain though, at some point, I will have my Saab turbo powered 480. I need a 480 in my life that can smoke some underendowed arsehole in an M3! For me, this is defining satisfaction :)

Tomorrow I tackle engine removal from the blue one (now reassigned as the Saab-Olvo because it looks a bit of a shitheap and I want a nice one to drive round in if I can't have the 9-3, bodywork can be dealt with if it's off the road and being hacked to bits to shove the 'massive square peg' into the 'tiny round hole' so to speak!) and hopefully get the black one driving in the next month or so, then it's Saab stripdown (whatever may happen afterwards) and then I can take the first big step of actually offering the Saab powertrain into the 480 so I know exactly where I stand, then I can decide whether to rebuild the Saab and wait for another donor (having taken the opportunity to mock up so I have mounts etc sorted and whatever chopping of the 480 that's required done) or just go ahead with it and then decide the fate of the 9-3 down the line. As I said, lots of options, an open mind and no hurry to decide. I don't mind all the work, I'm never happier than when covered in grease, oil, shite and wielding a spanner so it's all good fun :lol:
O.C. 480 D.

Post Reply