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karmannghias.org Blog for the Alken D2 and Sonett 3


Day 50 – Saturday April 4

Posted in Sonett III by Administrator on the April 5th, 2009

Today we took 2 or 3 steps forward and possibly a ton backwards. We decided to crank the engine. Well everything went good until we hit the third and finally click on the ignition. Then we heard some “expensive noises”(old friend of ours). The clutch was catching on something when the motor would begin to turn over. Then we cranked it with the key and no clutch, worked fine. then did it again after pumping the clutch, no problem. hmmmmm Still even after a couple failures it was a cool feeling and sound :D . It appears though that either: A. the engine needs to be pulled from the clutch or B. the motor needs to run to free the flywheels needs to be freed from the clutch.

Clutch Disengaged:

Clutch Engaged:

Well for some of our work we needed light, but the extension cord came unplugged and to plug that end we need some like talk about irony. So Dad got inventive. Using the flash on the camera, he could finally see behind the storage racks and located the receptable.

We then took the Valve Pan covers off, really clean in there, wow.

Day 49 – Friday April 3

Posted in Sonett III by Administrator on the April 5th, 2009

Took some concrete cleaner to the gas tank. We might have diluted it too much but it cleaned it a little. We are not going to seal it since the rust was not bad and some liners seem to come off.

Day 47/48 – Wednesday/Thursday April 1/2

Posted in Sonett III by Administrator on the April 5th, 2009

Drove the Sonett down the road, just kidding, April fools.

Day 46 – Tuesday March 31

Posted in Sonett III by Administrator on the April 5th, 2009

Sent sender off to Palo Alto.

Day 45 – Monday March 30

Posted in Sonett III by Blade3562 on the March 31st, 2009

Today we didn’t do very much other than clean out the inside of the tank. It’s a little bit rusty in there and most likely needs some sort of coating. We sent an email off to Palo Alto about or sending unit and it looks like we’ll be shipping it out to them tomorrow or later this week for a rebuild.

Day 44 – Sunday March 29

Posted in Sonett III by Administrator on the March 29th, 2009

Today involved electrical systems testing. We put the the battery in and tested out our rear lights. After several hours of misunderstanding and miscommunication the lights work fully and almost perfectly. The interior electircal systems work fine, all except the gas gauge. The problem with the gas gauge is that even though the tank is empy it read full, We’re trying to figure out the problem and eventually will.

I also was searching through the saabnet.com forums and found a really sweet set of rims for the Sonett, but it doesn’t look like my dad wants to get them.

Well we decided to rip the tank out, first step was the sensing gauge.

Then the Tank

Day 43 – Saturday March 28

Posted in Sonett III by Administrator on the March 29th, 2009

Worked on cleaning the trunk of the car and then moved on to installing the right rear tail light.

Adam decided it was better to get inside the rear to do the cleaning. If we left out the spare maybe a third person or the dog could be anchored in there.

Apparently when Perry owned the car there was a run away picnic table that took out the right rear tail light. He picked up another and we went to install it today. The fiberglass was torn in the corners by the license light, we used a larger washer on the back side to secure it. This picture shows the light as it was hanging out.

I guess the mice thought this was an easy way into the car instead of opening the door. The went in through the light and build a nice nest in the fiber glass. Looks like we will put in new panels before closing things up.

We had to so some serious cleaning on the replacement housing before installing.

Once installed we took a couple of rear pictures. First though we decided to polish up the black panel. Came out pretty good.


Day 42 – Friday March 27

Posted in Sonett III by Administrator on the March 29th, 2009

Went through Haynes manual we picked up.

Also updated the purchased parts page.

Day 38/41 – Monday/Thursday March 23/26

Posted in Sonett III by Blade3562 on the March 27th, 2009

Spring Break!!!!!!!!!

Tomorrow I’m going to clean the rear trunk area other than that its a break and i was relaxing.

Day 37 – Sunday March 22

Posted in Sonett III by Administrator on the March 23rd, 2009

Well, I was going to spray some weeds but decided to stop by the Saab. I thought I’d put some gas in the tank and rinse it out so I took of the line to the fuel pump. I only put a gallon in the tank and had milk jug over the end……….nothing, rats.

I took up the back panel to see the tank and then realized that the outlet was obtained by going through the cabin. I found the nut and loosened it ever so slightly…..nothing. Well, since I had the brake power bleeder I thougt I suck the line out. It had forced one of the small rubber tips in the hose from the fuel pump…….. nothing.

I took car and brought the rear line out through the hole behind the back seat. It was plugged, how bad could it be. I used the tube from the carb cleaner and slowly forced it down in the line. When I push the button all the carb cleaner came back to me. Well, lets try the front. Karen had some small craft wire that I twisted to two strands with the drill. I got it the whole way back to the firewall. I wouldn’t make the jump from the one small rubber hose. So I thought I would use the drill like a roto rooter. That worked great, it got the cable stuck and I couldn’t pull it out.

For the next hourk plus I tooke the line apart at the firewall. There was the not in the wire. I cut it off and pulled it out. The good news was that it was clean. I had a thin aluminum wire that I started to force from the rear of the line. It took a while but I finally got it clean. Next, I spent 1/2 hour hooking the front line back up. With the power bleeder hooked up I pulled some carb cleaner the whole way through.

You are wondering why no gas is coming from the tank? Well it was plugged. I packed the area with rags below the outlet and stuck a wood dowel up the hole. I got about 10 year old gas flowing a little so I hooked up the line. I filled 2 milk jugs with new/old fuel. Check the picture later.

After cycling another gallon of fuel through I opened the line again at the bottom of the tank. I jused a small drill bit to open the bottom of the tank the rest of the way. 2 more gallons of clean fuel then I was done. What was a harmless walk by the Saab ended up being a 4 hour adventure.

Adam put the interior back together, oh, I had to take out everything I put in last night.

I worked on the clutch again. We were getting full travel but it looked like the clutch was stuck to the flywheel. Adam pressed in the clutch, the forks moved, but the engine still turned. As one point we caugth the lever and bent it up a little. I forced it back down and it seemed OK. Not sure how to get the clutch to break free. Maybe there is a trick so I posted a note on the Saab Net.

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