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karmannghias.org Blog for the Alken D2 and Sonett 3


Day 22 – Saturday March 7

Posted in Sonett III by Administrator on the March 8th, 2009

Lots of work today and we didn’t get started until 12:00 (i.e. sleeping beauty must have been up gaming last night). The two of us spent a good 7 hours on the car today.

First, we finished off the left rear drum. First we had to press in the new bearings. Not sure of the correct technique but we press the inner bearing in first follwed by inserting the clip and then seal. The inner sleave and outer bearing were next and were pressed in from the opposite side. we made sure the the inner sleave didn’t bind and was just barely movable. This would allow us to slide the drum on and have everything align. A while back we picked up a 1 inch drive socket set made in China. Cost bout $60 but the sockets come in handy when pressing anything, you select the right sized socket for the job.

This drum went on easy since it was newly cut (not lip or rust to interfere with the shoes). The adjuster was fully in to maintain full clearance. We worked the brake adjuster all the way in until the brakes were tight. Then we backed it off until it turned without any scuffing. Not sure how Saabs work but we need the brakes to “center up” from applying them before we really adjust them. One socket set has some sockets for square nuts (not hex nuts). This square socket matched up nicely with square brake adjuster shaft and allowed us to use a ratchet as we don’t have the stock Saav tool. We might keep this in the Sonett tool kit. This must be for Days 14, 18, and 19 also work with this brake drum.

Next we moved over to the right rear. Adam did most of the work here after seeing how we did the other side. While he was working on the drum I removed the passenger seat belt so that access could be gained to the brake lines. As he completed tear down of the drum I replaced the flexible line.

One item of interest was a gasket between the slave cylinder and the backing plate. We noticed it when removing the cylinder. This slave cylinder also had a copper bleeder valve.

The parts washer helped to clean everything up and we have the brake drum ready to go out and be but. Next on the list was the left front.

With the left front off the ground it was easy to see that the freewheel works. We had the car in gear and could move the selector in and out which showed us that the wheels would move in the freewheel position and stay locked when it was engaged.

Pulling the hub off the front wheel was pretty easy. Getting the castle nut off was hard because with all of the sockets I had a 33 mm did not exist. I’ll have to see if my brother has a socket I can borrow. I did the unthinkable and used a large cresent wrench to free the nut which worked OK. I saw some Saab posting a about using the Saab puller. We had an old standard puller that worked quite well.

After everything was apart, it was off to the parts washer. The caliper seemed in very good conditon withouth any leaks. The piston appeared to be a chromed piston. We forced it out of its 35 year old home with some air. It was easy to see that the rubber ring with the colors on it goes in the inside of the housing. The outside seal is the one that has two wipers on it. We included an exploded view of the old and new parts.

Day 21 – Friday March 6

Posted in Sonett III by Administrator on the March 7th, 2009

Took a break today and went down to Akron to pick up a Herbie deck lid that was sent by Greyhound from California. We mounted the decklid in our theater room which is Herbie Themed. I’m sure we’ll put a Sonett car in there too.

Day 20 – Thursday March 5

Posted in Sonett III by Administrator on the March 6th, 2009

It was 60 degrees today. Couldn’t work on the Saab because it didn’t seem natural. All of the other days it was 20 or below in the garage.

We did buy a Haynes manual from the Nines for $40.

Adam spent a little time detailing the carpets.

Last night I finished a “page” dedicated to the parts we have bought. We are approaching $2000. If we buy front wheel bearings we’ll be there. The parts page is a little hard to create because I did it in excel and used the print screen to get the image for the page. I want to creat a page for parts needed too.

Parts Ordered

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

Day 19 – Wednesday March 4

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

Stopped by Allied and orderd the bearings. It might take about 3 days to get everything.



We purchased a second water pump for $70. I picked it up on that auction site. It is an original Meyle pump. While it has the curved vanes they are not machined like the orignal pump. I still wonder how to change out the original impeller and put it on a new rebuilt pump. We will keep the one from Skandix as a spare. Other photos back on Day 8 of the original pump.

Day 18 – Tuesday March 3

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

Picked up the rear drum on the way home. Not bad for $10 to cut it but they cut it a little deeper than I wanted.

I looked on-line to find a local bearing inc for bearings and seals. I ended up going to Allied where they had bearings and seals.

I put some links in for you to check the site out:
6304 outer bearing, 52 mm outer, 20 mm shaft, 15 mm width – $14.93
6305 inner bearing, 62 mm outer, 25 mm shaft, 17 mm width – $24.38
seal, 62 mm outer, 40 mm shaft, 10 mm width – $4.84
“6304 Outer”
“6305 Inner”
“Seal”

I will send the master cylinder to Chip Lamb for a rebuild. He was one of the first people I emailed before buying the Sonett so I wanted to support him. He seems to have a great reputation too. The rebuild will be $330 and then I will pick up a fuel pump for $90. I think Skandix has a fuel pump too for $60 if you need one. I guess rebuild kits are not available. It will be nice to have the whole system replaced.
“Chip Lamb”

I will see if I am tempted to replace the front wheel bearings once I get there.

Oh, we did finish the assemplby of the clust master cylinder and slave. These are the original components to the car and we’ll keep the new slave that we bought as a spare. The part exploded view seems to show a small rubber washer that goes over the shaft to the clutch so we put one in as a wiper.

Day 17 – Monday March 2

Posted in Sonett III by Administrator on the March 3rd, 2009

What a bit**. When Karen walked by the Sonett I made this off comment that the master cylinder, way down in there, seemed to be working OK. She said, “What’s it for”. I said for the brakes. She said change it. Oh well, 2 hrs later I wrestled it out of there. Not bad with everything else I removed, it was more accessable (I almost wrote easier to get at). I feel good that it is out be now I need to have it rebuilt. Since it seems OK maybe it will not need a sleave (Adam to get the pics up later).

On the way home I stopped at the Firestone tire store in Twinsburg. They can cut the rear drums for me to trim them up. The owner, a family owned business, said their are usually two drums. I explained I only have enough room to get one off at a time. I told him to take the smallest amount off possible.

Day 16 – Sunday March 1st

Posted in Sonett III by Administrator on the March 2nd, 2009

Went up to the Napa in Twinsburg. Seems they don’t do machine work, must have only been the shop over in Streetsboro. The also gave me the name of a brake shop for me to check out on the way home on Monday.

We tried to match up some SKF bearings too but they weren’t able help. Seems like I’ll have to stop in at Bearings, inc. to see if they can match up the rear wheel bearings.

Couldn’t stay away from the auto show. Had to go and visit again today.

There was some discussion on the battery hold down. I did find a tab for one rod to bolt onto but not sure about the other side. I will have to post this on the Sonett site. I also wonder it this rear compartment was painted gray.

Day 15 – Saturday February 28th

Posted in Sonett III by Administrator on the March 2nd, 2009

Drove to NTB to see if they could cut the one rear drum we pulled off. They didn’t do machine work but suggested NAPA.

Later we went to the Cleveland Auto Show. The 370Z was lookin sharp as was the Audi A8.

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