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Old 07-17-2019, 10:08 PM   #1
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Glacier Blue 9-5 Aero Wagon Project

The story is: My girlfriend has enjoyed driving my wagon over the past 2 years claiming that it "wants to be driven fast". Given that we each have a big dog, the wagon works out great. We tossed around the idea that we would get her a wagon one day. She saw the Glacier Blue color on the internet and decided that was the color she wanted. I kind of laughed it off as I knew the color was super rare. As fate would have it, one popped up a few months later in Monterey, CA. I made it work out as part of a trip to move my brother from Ventura, CA to Nashville, TN. (I am currently spending the summer in Boulder, CO). We packed up the wagon and my SUV and loaded everything east. It all worked out pretty well.

I knew the color combination on a aero wagon was rare, but it turns out that this car is 1 of 13 Aero wagons. 10 were automatic, 3 were manual. That being said, the car needs a lot of love. It was a deceptive California car that started its life in Massachusetts. I knew about the dog leg rust that was on it, but of course there's more where that came from. The seller told me that the incorrect hood was on it because he lost his temper on the original one. Which he did, but only after he had a little run in with a deer. (the part I didn't know about until I drove 1200 miles). The radiator support is kind of kinked up and the condenser, radiator, and rad fan are likely going to need replacement. The Aero bumper is missing the bottom lip and is cracked from the deer incident. It will need replacing.

At 193k on the motor, I knew that I was getting into a project regardless of the body work.

However, I have no regrets. I love the car and so does Anna. It may take a couple of years, but we'll bring it back to it's former glory.
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-1992 9000 T5
-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue
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Old 07-17-2019, 10:13 PM   #2
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Some pictures:

An epic California sunset right after I loaded it up:















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-1992 9000 T5
-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue
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Old 07-23-2019, 01:29 PM   #3
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I love the color

Sent from my SM-G930F using Tapatalk
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Old 07-24-2019, 03:08 PM   #4
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Very nice score! I'm sure it will clean up well.
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Old 08-12-2019, 03:28 AM   #5
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Got a lot accomplished on the wagon in the past couple of weeks. Finished up the rust repair on the dog legs and driver door that had been started when I got the car, cleaned up the scratches / damage on the rear bumper, buffed head lights out, charged up the AC and did a new fan speed controller. I also did a new radiator, and new (used) radiator fan and condenser to replace all the stuff that was cracked up front from the impact. We picked up a hitch and installed for the bike rack. Other new stuff includes EGR valve, MAF, and Bluetooth stereo and dashkit.













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-1992 9000 T5
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-2004 9-5 Aero Wagon - Glacier Blue

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Old 08-12-2019, 03:53 AM   #6
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Anna flew into Colorado and we took the wagon to Saab Owner's Convention in Loveland. Had a blast meeting everyone, but I'll admit I was embarrassed parking this car next to other 9-5's with the hood in the condition that it was in.



After SOC, we made the 1,200 drive home. Luckily we had no issues. I'm pretty pleased with the car so far.



Dropped the hood off for paint. Can't wait for the results.



The two wagons together

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-1992 9000 T5
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-2004 9-5 Aero Wagon - Glacier Blue

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Old 08-16-2019, 08:22 AM   #7
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Nice pickup! That's a great color on the 9-5
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Old 08-16-2019, 09:29 PM   #8
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Nice looking wagon. Did you do some body work on the hood before sending it off for paint? How did you go about the rust repair on the dog legs? Do you rattle can them?
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Old 08-18-2019, 10:43 AM   #9
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Quote:
Originally Posted by Tboy View Post
Nice looking wagon. Did you do some body work on the hood before sending it off for paint? How did you go about the rust repair on the dog legs? Do you rattle can them?
When I picked up the car in California and got it to Denver, I had about 3-4 weeks to tweak things on it before Saab Owner's convention. I really wanted to get the hood looking decent, so I tried to see how a primer filler would hide the clearcoat defects. I was going to get aerosol paint cans and put a coat on the hood so it wouldn't be such an eyesore. It didn't do a horrible job, but the cost in materials would've been more than I wanted to spend since I knew I was going to have it professionally painted once I got home. Unfortunately it went to SOC like that.

The last owner had already started the rust repair by stripping it down to bare metal and used body filler. All I had to do with the dog legs was spray them. I had to redo the driver door because it didn't look right. As far as painting, I used automotivetouchuppaint.com to get aerosol cans of the correct paint code and then cleared over it. I've used them for many projects in the past. Always pretty satisfied with the results.

All of the rust repair is temporary. One day I'll patch in new metal.
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-1992 9000 T5
-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue
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Old 08-18-2019, 10:45 AM   #10
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Quote:
Originally Posted by jpgroth View Post
Nice pickup! That's a great color on the 9-5
Thanks! We love it
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Old 09-15-2019, 05:03 AM   #11
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The dash that came with the car had some scuffs on it and some deep scratches. We decided to do a dash swap with a textured black dash from the 06+ Dame Edna 9-5. We liked the look of the dash being all black instead of shiny black and gray. When we got to the junkyard, the black carpeting was in really good shape, so we pulled that as well. After $80 in parts, the interior is in pretty good shape.









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-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue
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Old 10-04-2019, 05:13 AM   #12
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We have done a lot of work on the car recently. Since the rear suspension blew out, I decided to put D2 Coilovers on my Espresso wagon and donate my Bilstein B8's and stock Aero springs to the Glacier Blue wagon. They are in great shape and seem to be low mileage.















I am also working on redoing all of the rear bushings. I got trailing arms that are in great shape from the junkyard and installed new rose bushings and Powerflex trailing arm bushings. Both sides are on the car now. I have the inner control arm bushings to go on, but waiting on some non-rusty control arms / adjustable lower control arms before I install them.





Used parts pile is growing:




I also did the "666" modification for the headlights. This modification allows the center lights to come on simultaneously with the xenon high beams. I highly recommend this to anyone that has these Aero Xenon lights. $13 upgrade. The Bosch part number for the proper relay is Bosch 0332015006



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-1992 9000 T5
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-2004 9-5 Aero Wagon - Glacier Blue

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Old 10-04-2019, 05:42 AM   #13
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I've heard of the relay mod but never looked far into it, is it as simple as buying the relay and swapping it with what the car came with?

And it only happens with the brights are on, right?
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Old 10-04-2019, 07:26 AM   #14
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Quote:
Originally Posted by 9Kwrecker View Post
I've heard of the relay mod but never looked far into it, is it as simple as buying the relay and swapping it with what the car came with?

And it only happens with the brights are on, right?
Yeah, I wasn't super clear on it until I got the relay and tested it out. With the stock Aero xenons, when you hit the brights, the xenons just get brighter. The lights towards the grill don't come on. So this relay allows the center lights to come on in addition to the xenons getting brighter. So it's super bright.

Yeah, all this changes is the condition when you hit the brights on the stalk. Beyond that, everything is normal.

It is as simple as replacing the stock relay with this Bosch one. I added a picture to the original post indicating which one.
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-1992 9000 T5
-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue
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Old 10-14-2019, 11:30 AM   #15
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I wrote a thread on it if you search. I made a jumper wire with spade terminals for approximately free but if there is a proper relay for a few bucks, thats probably worth it. Really nice improvement in high beam performance. Its like getting an extra set of high beams. And the combination of xenon and halogen makes a lot of light.
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Old 10-16-2019, 03:51 AM   #16
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Quote:
Originally Posted by BuHuSPG View Post
I wrote a thread on it if you search. I made a jumper wire with spade terminals for approximately free but if there is a proper relay for a few bucks, thats probably worth it. Really nice improvement in high beam performance. Its like getting an extra set of high beams. And the combination of xenon and halogen makes a lot of light.
Ah nice! I admire the ingenuity. I'm ok at wiring, but I'd rather have a proper relay if possible just to be on the safe side. I was discouraged when I could only find the relay as a "666 modification" from eEuropart's. Then I remembered I had a car with the relay, so I just pulled the Bosch PN from it and found it cheaper from FCPeuro and Rockauto (comparable pricing).
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-2004 9-5 Aero Wagon - Glacier Blue
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Old 10-21-2019, 06:40 AM   #17
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We had a long weekend, so naturally I spent the entire time wrenching. The water pump had started to leak really bad after I was pressure washing the engine bay, so I went ahead and did the water pump and silicone cooling hoses. The kit came with intercooler hoses as well, so those got put on too.

The bolts on the water pump housing were seized and I stripped the bolts. Perfect excuse to replace it with a shiny used housing. Looks so much better. I know you never see it, but I know it's there.

When I pulled the water pump housing from the junkyard, I also grabbed the pair of metal tubes that run to the water pump from the driver side of the engine bay. The ones on the car were rusty of course.









Finally got the hood back. I couldn't be more pleased with the turn out. It looks amazing and completely transformed the look of the car. After 4 months, it finally doesn't feel ghetto. Having the hood the proper color makes the entire car look like a deeper blue in my opinion. I know it's all just brain tricks, but either way, the car looks soo much better. We fitted a new Saab emblem to top it off.












We also got the Hirsch replica spoiler back from the same place that did the hood and got it mounted up. It was a little more tricky than my other wagon spoiler I did because of the angle of the mounting holes. I love this look on the wagon.








We got the valve cover back from the powdercoating place and fitted it with a new valve cover gasket and stainless hardware. We debated a variation of the Glacier Blue color, but with the blue silicone hoses, I'm glad we went with the textured purple for contrast.









The upper engine mount bracket was looking a little rough next to the new valve cover, so I primed and painted with VHT Aluminum finish. The result exceeded expectations.

Primed:



Painted:



Picture of the engine bay shortly after I picked the car up 4 months ago. It's come a long way.




I got sick of looking at the cracked and tattered seal on the windshield cowl, so I took a razor and cut it all off and sprayed the cowl with a Rustoleum bed liner. Still looking for a new seal solution to replace the original if anyone has any experience doing this. I also had the wiper arms powdercoated black at the same time we did the valve cover. Really cleaned up the look of this area.





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Old 10-21-2019, 06:55 AM   #18
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This car is looking so much better than when you first got it, great work.

Questions:
Did the templates I sent you have the holes marked in the right spots on them?
Did you also use double-sided tape to secure it, or just the screws?

On the cowl cover, did you need a puller to get the wiper arms off or were you able to work them off by hand?
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Old 10-21-2019, 07:33 AM   #19
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Quote:
Originally Posted by 9Kwrecker View Post
This car is looking so much better than when you first got it, great work.

Questions:
Did the templates I sent you have the holes marked in the right spots on them?
Thanks so much! Shame everyone at SOC saw it before I could really dig into it.

The templates were very close. The first side I did went well. The problems started to arise when I drilled holes for the second side. I think the problem was related to the potential of the spoiler to bow up or down since it's a hoop. I could make everything line up if I started to force the spoiler up, but I didn't want to keep it in compression, so I just drilled all 4 holes larger. If I were to do it again, I would have done one side, then used a combination of the template and mocking up the spoiler actually bolted to the car on the one side to locate the second set of mounting holes. (Really obvious in retrospect). Thanks again for the templates!





The tape kind of obscures the edges, but it is lined up to the best of my ability given the tools. hahah.

Quote:
Originally Posted by 9Kwrecker View Post
Did you also use double-sided tape to secure it, or just the screws?
I did use double sided tape. Unfortunately didn't take any pictures of the mounting set up, but I used 3M automotive molding tape. I also used a foamy type of washer in between the spoiler and body that the body shop gave me. Since I had to make the holes so large, I was worried about water leakage around the mounting bolts, so I used silicone around each bolt. I don't even know that those holes communicate with the interior of the car, but I'd rather do it to be on the safe side.

Quote:
Originally Posted by 9Kwrecker View Post
On the cowl cover, did you need a puller to get the wiper arms off or were you able to work them off by hand?
No, I didn't use a puller. You can get the wiper arms off in a matter of seconds if you extend the arm and rock it firmly back and forth towards and away from the car. I have a video of me doing it to debunk the puller thing. I'll see if I can get it uploaded.

Edit: Uploaded that video. Don't mind my super disheveled post-exam look.

https://youtu.be/ue6diagdYlQ
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-1992 9000 T5
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-2004 9-5 Aero Wagon - Glacier Blue

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Old 10-21-2019, 07:59 AM   #20
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A couple of weeks back I decided to "touch up" the wheels using the same paint the previous owner used. This was meant to be a small thing to hold us over until we can afford to have the wheels properly refinished. The previous owner didn't use a clear coat and the paint was wearing down to the primer in places. Naturally, I ended up doing more than a touch up. I sanded down the lips and faces and re-primed and painted each one. A couple of days and a lot of elbow grease later, they actually don't look too bad for a Rust-oleum rattle can job. (Obviously not my first choice, was just trying to use what the previous owner used). I used a 2k clearcoat and it actually took a lot of the cheap looking metallic sheen out of the finish. I'm pretty pleased with the results considering it cost about $15 in materials. We also fitted new wheel emblems to finish out the look that were the proper "Saab" vs. the "Saab-Scania" ones that were on there.











On the car:



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-2004 9-5 Aero Wagon - Glacier Blue

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