1994/L Classic 900 Commemorative Edition Convertible

Brief History
This is a customers car, which he has been owned from new. It is a USA model Commemorative Edition, the last of the classic 900 models to be produced for the USA market. This car is build number 444/500
The car was imported to the UK when the owner moved here, a few years ago.
Having covered less than 90000 miles, and being one owner, this car is still in very good condition. However time is catching up on it, and the hood needs replacing, the power operation of the hood is not working, the engine could benefit from a basic overhaul, the paintwork from refreshing and a general tidy up. Also a conversion from Left Hand Drive to Right Hand Drive is being carried out.

The 900 Commemorative Edition Turbo Convertible   (from www.saabce.com )
The 900 Commemorative Edition Turbo Convertible was offered in the US market in September of 1993. This model was only available as a convertible with a manual transmission. It had a 185 Hp engine which gave it the same performance as the 1993 Commemorative Edition Turbo Coupe. The extra horsepower was achieved through the modified "red box" APC, a 2.8bar fuel pressure regulator, and a special distributor with enhanced vacuum advance. The exterior of the car was "Nova" black metallic. It is the only Saab model that had this color. It also had tan leather interior like the 1993, but the seats were given a two-tone treatment by adding charcoal grey piping (they called it black, but it is the same piping used on the charcoal grey leather interiors). All had tan canvass tops. It did not share the 1993 CE's lowered suspension. Only a limited number of 500 were produced for the U.S. market (VINs ending in 008000-008500). They did not get the gold numbered badge like the 1993 CEs. All included leather interior, a burled walnut instrument panel facia, a leather gear knob and boot, and special charcoal gray metallic directional alloy wheels with polished outer rims. Some cars had later dealer-installed options added when they were purchased; like walnut ash trays and gear knobs, black tops, and SPG body panels.

Shedule of work required:
Remove engine/gearbox and all engine bay wiring, LHD steering rack, LHD wiper mechanism, LHD bulkhead shield, front panel, lights.
Remove interior (seats, LHD carpets, door cards etc..) remove hood. totally remove LHD dashboard, LHD facia, LHD pedal box, LHD wiring, LHD consoles, LHD knee pad, LHD sunvisors, airbag components etc..
Remove windscreen and all exterior fittings, LHD mirrors, bumpers, rubbing strips, roof spoilers, door handles/locks, badges, arch trims etc..
Grit blast enginebay and lower inner wings, make good any corrosion found.
Full respray in original colour, to include engine bay, door shuts, inside boot, inside bonnet etc etc..
Complete check of engine and gearbox, replace items as necessary including headgasket. 
Refit all components to convert to RHD
Refit engine/gearbox and other components into engine bay.
Refurbish hydraulic hood mechanism and fit new hood (tan colour)
Reassemble all interior and exterior fittings.
Extended road tests and then handover back to client.

Time scale

This project is expected to take 10-12 weeks to completion (due to Christmas/New Year delays).  Car delivered to us 25th November 2009
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Pictures of the car before work commenced: - click pictures to enlarge
w/c 07/12/09 Removing the engine and stripping the engine bay:
Interior removal:
Swapping over to a RHD steering rack and steering colunm:
w/c 14/12/09 Exterior trim removal:
w/c 21/12/2009 The car is now totally stripped and has been transported to the bodyshop for grit blasting of the enginebay, removal of windscreen and then full respray in the original colour.
w/c 11/01/2010 The car has now been painted and a new windscreen fitted. Now back at the workshop. Next job is to remove the old hood and refit with a brand new hood, also service/repair/replace the hood hydraulics/motor as required. Also the wheels will be removed for refurbishing.
Back inside the workshop with the wheels replaced by temporary ones (the original wheels are now being refurbished).
w/c 18/01/2010  RHD pedal assembly fitted and starting to refit the engine bay components and wiring:
w/c 25/01/2010 Engine bay componentry continues to be refurbished and fitted. The oil cooler now has a replacement powder coated mounting frame. Front panel aligned and fitted securely, with powder coated strengthening plates at the top edges.
Lights fitted to front and rear (uk spec lights including integrated rear fog lamp). rear panel also fitted and aligned. door locks fitted. Engine bay, chassis rails, inside doors, inside rear wings, boot floor etc all treated to anti corrosion dinitrol treatment. window motors serviced and lubricated. Door mirrors fitted with correct glass for RHD. The rear towing eye unit and the two bumper mounting brackets were sand blasted to remove surface corrosion and then powder coated before refitting.
The wheels have been fully refurbished, and fitted with new tyres. These have been put into storage and will not be fitted to the vehicle until later in the build.
w/c 01/02/2010 Dinitrol rust proofing added to inside of all box sections, boot, doors, innder arches, rear inner wings, under rear seat, cahssis rails etc etc...   A horrible job to do but essential to preserve all our hard work!
With the engine/gearbox assembly removed it was time to examine the units in more detail.
It was discovered that at somepoint in its history the sump drain plug housing on the gearbox had been damaged and repaired with liquid weld! After discussing options with the owner, he decided that we would get the gearbox rebuilt onto a replacement casing. Whilst this was being done the gearbox internals would be reconditioned.  Pictures show the engine and gearbox after splitting and initial disassembly.
w/c 015/02/2010  Hood hydraulic system removed and serviced. O/S hydraulic ram replaced and fluid refilled. System replaced and checked. New hood fitted. Note pictures show part of the fitting. Final fitted pictures with the hood fully closed and under tension will be added soon.
Work continues on the engine, replacing many internal and external components including timing chain. The block has been repainted and many external parts powder coated including inlet manifold, cam cover, timing chain casing, alternator brackets, engine mounting brackets etc etc.
w/c 22/02/2010  The reconditioned gearbox has been completed and mated to the engine. Final assembly of all engine components completed:
New brake discs, pads, hoses and full brake caliper service carried out:
Engine now in the car, all ancillaries fitted and electricals connected.  Fluids filled and engine started and test run. No issues!
01/03/2010TO DO: Double check all under dash wiring systems are working before dashboard assembly is fitted - Items such as cruise control, instruments, ECU etc. Once all sorted the instruments, dashboard, walnut fascia can be fitted. Sound proofing and carpets followed by seats, door cards and interior trim. Final assembly of all external trim and fitment of the refurbished wheels.
01/04/2010.  The finished car!    
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