Thanks!
Plan is to get it running for now, Freezeout Hillclimb is 7 weeks out and I don't want to use the BMW if I don't have to. But I already have future plans to relocate a much larger fanned oil cooler behind the DS headlight bucket where the old intercooler was...
But w/ the 2 'new' 9^5's (06 sedan, 04 Aero Wagon), I'm broke.
The 06 was pretty solid from the start (besides motor mounts), but the Aero has a broken piston. I should start a thread on that one...

John

Well, it's been a year and Frank if finally back up and running!
I bought a new T5 harness and flywheel from Jordan and should have it out for a test drive this weekend.

There is a test-n-tune at the local drag strip in a month, so I'd like to be there for that. Shooting for 12.39 @ 110, but we'll see how much weight I can get out of the car. After that, I'll bring it over to Bend and start on the EPS.

I'll try to post some pics/vids this weekend.

John

All done.
I fabbed up a new turbo outlet pipe this week and have been driving it a bit.
Engine is running great and all the weight savings are really noticeable.
Transmission is working great after replacing the 3rd gear synchro spring.
I've got the Mitsu turbo on it right now, but that won't last.




Of course there is still cleanup work. I want to replace the stock oil cooler with a Volvo unit I have, then an oil cooler/filter for the trans.

I used a Volvo alternator for extra clearance around the brake booster:

Nice work. What is the scoop on the Con-rods and pistons?

Light weight I hope!

The rods are the 2RZ rods I got from Eagle. You can see the second cut I had to make to the rod journal to make the SAAB bearings fit.

The pistons are Race-Tecs I had made for the project. They incorporate the .5mm difference in rod length from the Eagles and are lighter than factory.
Calculated compression (with the 2.3 head and 94mm bore) should be around 8.8 cr.
After this photo I sent them out to have the crowns and skirts coated. The name addition was a surprise...and no extra cost!

Between the rods and the pistons, I saved .8Kg/hole. The flywheels saves me a few more pounds, though it's no lighter than my old one.

And yes, I sent the turbo outlet pipe out for welding ; )

Impressive build. That is a great weight savings for linear/rotation mass.
Personalized pistons is the icing on the cake.
Welding aluminum casting is always challenging, so I don't blame you. Just depends on the planet alignment.

I built two new additions to my T5 harness and now have a working speedo and my car doesn't stall when I come to a stop.

I installed a 9000 speed sensor on my 900 trans and ran the wires right where the old cable would have been. I cut up a 9000 speedo to fit the 99 pod. I wasn't sure where to get +12v, the power lead is gn/wt, so instead of using the instrument power (fuse 4, br/wt), I decided to use the same gr/wt +15 circuit that powers the ECU.

The speed would be reasonably accurate, but the 9000 needle needs to be shifted about 35 degrees. It reads 20mph low at all speeds. I'll fix that later. It's working and I don't want to pull it all back apart. I still have GPS.
The odo runs 5% high. Don't think I care. The plan is to have a new dial sticker made and realign the needle using one from a 99...and run 5% shorter tires : )



Best part, it runs perfect now. No stalling on warmup (both this system and the previous would stall once during warmup), and no stall when I get off the throttle.

It was so fun to drive today, when I got home, I passed on by and went for another 24 mile lap! I'm still only running base boost while I break it in, but for most driving, I just leave it in 4th! It pulls from 1500 right on up.

I replaced the rear 8" 350# springs with 10" 300# Eibach units. Car really likes them.

Lots of details to clean up before April. Like figuring out why my blinkers stopped working...

Another quick update,

I installed a quick release to the steering wheel,


Fixed the bend between the IC and the TB


And I installed some blue halo headlamps,

Nice, great to see you are still having fun with Frank.

Some new wheels and tires this year.
The new 245/40-15 on 8" rims vs. the old 225/45-15 on 7" rims.

Always enjoy the little updates. Hoping I can see it at Freezeout this year!