1976 Saab 96 V4

Initial Assessment & "Head of Bad News"

Our lead mechanic, George, didn't have to look far to find the issues. While the car appeared "straight" at first glance, a deeper dive revealed:

• Widespread Rust: The floor pans, inner arches, and door bottoms were heavily corroded [05:42].
• Hidden Damage: Previous repairs had been "skimmed over" with thick layers of filler rather than proper metalwork [11:13].
• Perished Components: Braking and fuel lines were "crispy" and required a complete overhaul [05:02].

The Bare Metal Process

To ensure this restoration would last another 50 years, we committed to a total strip-down.

• The Strip: Every window, seat, and trim piece was removed [08:27]. We used a combination of heat guns and paint strippers to take the body back to raw steel, uncovering every dent and hidden hole [10:27].
• Precision Fabrication: With many Saab body panels no longer available, our fabrication expert, Woody, hand-crafted new metal sections for the boot floor and inner wheel arches [14:52].
• Superior Protection: After welding, the entire underside and arches were coated in epoxy primer followed by a rubberised bed liner. This creates a chip-resistant barrier that is actually better than the factory original finish [16:31].

Mechanical Rebirth: The Ford V4 Engine

The heart of the Saab is its compact Ford-sourced V4 engine.

• Complete Teardown: We pulled the engine to inspect for leaks and "years of neglect" [13:12].
• Cleaning & Seals: Every nut and bolt was cleaned, and the unit was rebuilt with fresh gaskets and accessories.
• The Result: After our team’s fettling, the engine fired up instantly on the bench, a testament to the simple, robust engineering of the era [14:28].

Finishing Touches

• Paint: The car received a flawless three-coat finish in its original "Scandi Green" [19:07].
• Sustainable Restoration: To stay environmentally conscious and manage costs, we opted to powder-coat the bumpers rather than re-chroming them, achieving a durable, high-quality look [19:07].
• Interior: The original seats were carefully repaired to maintain the "smell" and character the original family cherished.

The Result

After 800 hours of labour, we delivered what we believe is the finest Saab 96 on the road today. While the financial investment was significant, the result was a "factory-fresh" vehicle that moved its original owners to tears [19:50].

Whether it’s a quirky Saab or a classic camper, our team at The Classic Car Workshop applies the same level of obsessive detail to every project.