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Old 03-22-2020, 08:02 PM   #221
Waiex191
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1999 SL2
1998 SC2
Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

We started swapping out the window motor. Adam took off the inner panel.


I got the outer.


Adam took the old motor apart in the name of science.


We drilled the rivets out and used AN4 aircraft bolts to put it back on. I cleaned the regulator with WD-40 and then greased it.
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File Type: jpg IMG_20200322_172715844.jpg (91.5 KB, 125 views)
File Type: jpg IMG_20200322_173301203.jpg (98.5 KB, 156 views)
File Type: jpg IMG_20200322_181849223.jpg (73.2 KB, 123 views)
File Type: jpg IMG_20200322_184758608.jpg (91.2 KB, 145 views)
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Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-25-2020, 11:45 PM   #222
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

Quote:
Originally Posted by ErikTande View Post
I love this thread, keep it up!

Let me know if you figure out a good way to fix the door panel clip, I broke one of mine too. Stupid plastic gets SUPER brittle after 20 years.
First I sanded the busted tab so there were no irregular lines.


Then I roughed up the inside of the doorskin with some 60 grit.


The form is a flat piece of metal with plastic tape on it for release.




I cut out small rectangles to build up to the thickness of the skin. The larger ones overlap to the bottom of the doorskin. Acetone was used to clean before bonding.


Resin mixed up.


Here is the layup. Curing now.


To be continued...
Attached Images
File Type: jpg sanding time.jpg (65.9 KB, 104 views)
File Type: jpg roughed up.jpg (56.5 KB, 103 views)
File Type: jpg form.jpg (60.9 KB, 104 views)
File Type: jpg other side of form.jpg (63.6 KB, 103 views)
File Type: jpg cloth and acetone.jpg (68.5 KB, 103 views)
File Type: jpg mix resin.jpg (63.7 KB, 105 views)
File Type: jpg layup.jpg (52.3 KB, 106 views)
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Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-26-2020, 12:03 PM   #223
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

I popped off the mold. I made a pattern from a neighboring tab.


I'm not sure I need the anti-rotation things on my new tab. The fiberglass is probably tougher than the plastic.
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File Type: jpg door tab template.jpg (71.8 KB, 103 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-26-2020, 10:43 PM   #224
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

I made a better tool for locating the hole.


The tab is slightly oversize. I put a notch in the end.
Attached Images
File Type: jpg IMG_20200326_213333346_HDR.jpg (57.6 KB, 100 views)
File Type: jpg IMG_20200326_213738084_HDR.jpg (65.3 KB, 119 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-27-2020, 12:32 PM   #225
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

One busted and one cracked tab on the front mounts.


Here was the layup. Note I just put two plies of glass behind the cracked one.


Form pulled off.


All the tabs are either cracked or will crack, in my opinion. So I am putting two plies of fiberglass behind all of them.


Attached Images
File Type: jpg IMG_20200326_215908758_HDR.jpg (65.1 KB, 96 views)
File Type: jpg IMG_20200327_111907370_HDR.jpg (70.0 KB, 95 views)
File Type: jpg IMG_20200327_112243734.jpg (68.0 KB, 94 views)
File Type: jpg IMG_20200327_112124076.jpg (51.4 KB, 93 views)
File Type: jpg IMG_20200327_112146088.jpg (60.3 KB, 93 views)
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Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-27-2020, 01:13 PM   #226
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

Finished front mounts.


Need to reinforce the four rear mounts and I'm done.
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File Type: jpg IMG_20200327_121043735.jpg (73.4 KB, 95 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-27-2020, 04:17 PM   #227
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

Nice fix.
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Old 03-28-2020, 12:34 AM   #228
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

Thanks Mark!

So my wife had me cover the inside of the garage door in reflectix last year. I had some left over. Also our dishwasher died and I saved the sound blanket.


After I cut these things to size and glued them together, I taped them onto the car.
Attached Images
File Type: jpg dishwasher parts.jpg (48.9 KB, 90 views)
File Type: jpg tin foil door.jpg (57.4 KB, 91 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-28-2020, 08:01 PM   #229
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1999 SL2
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

Somebody here mentioned the Home Depot 3/4" grommet as a door lock seal.


Attached Images
File Type: jpg IMG_20200328_165218726.jpg (51.7 KB, 88 views)
File Type: jpg IMG_20200328_182110653.jpg (43.2 KB, 88 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-30-2020, 11:56 PM   #230
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

I took the passenger side skin off also. The remains of the factory door seal were held on with grey duct tape.


The sound blanket looked really thin and powdery.


Most of it was white dust inside the door.


The tab fix also works on the passenger side.


Only one broken tab and a couple cracked ones. I glassed them all.
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File Type: jpg IMG_20200329_213220179.jpg (67.9 KB, 84 views)
File Type: jpg IMG_20200329_213304548.jpg (60.7 KB, 86 views)
File Type: jpg IMG_20200329_213314870.jpg (64.0 KB, 86 views)
File Type: jpg pass side glass.jpg (66.9 KB, 87 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-31-2020, 10:07 PM   #231
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1999 SL2
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

This is disappointing - two of my tab reinforcements didn't bond well.
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File Type: jpg IMG_20200331_203219605.jpg (73.6 KB, 81 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 03-31-2020, 10:26 PM   #232
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1998 SL2
Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

Quote:
Originally Posted by Waiex191 View Post
This is disappointing - two of my tab reinforcements didn't bond well.
I have total trust that you will figure out a solution - even if you have to use your leather sewing machine to do so.
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Old 03-31-2020, 11:12 PM   #233
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1997 SL2
Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

I have this post from cgg17 saved in case I need it when I finally go to remove my door panels. Maybe it will work for you as well.

http://www.saturnfans.com/forums/sho...d.php?t=234708
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Old 04-01-2020, 12:04 AM   #234
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

Thanks Zeebins! I remember cgg17's post. In my case I think it was bad prep on those two tabs. Otherwise it has been awesome. I'm doing over the two tabs.

Tonight I cleaned out the inside of the door, cleaned and lubed the window tracks with dry silicone, cleaned the regulator sliders with WD-40 and greased them. I have another piece of reflectix cut out. Should be a lot quieter when I'm done. Also the passenger speaker had two loose screws, which explains the buzzing.
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File Type: jpg IMG_20200331_223859219.jpg (58.9 KB, 80 views)
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Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 04-02-2020, 11:23 PM   #235
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1999 SL2
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

One of my door panel hangers cracked.
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Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 04-04-2020, 04:43 PM   #236
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

The inner door panel cracked on the rear edge where the plastic rivet goes. I made this 7075-T6 replacement.


In the background is the carbs from my kid's 1984 Honda V30 Magna. He replaced the o-rings for the carb bowls and now they don't leak anymore.
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File Type: jpg IMG_20200404_120335380.jpg (52.7 KB, 71 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 04-04-2020, 06:59 PM   #237
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1999 SL2
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

I busted the dome light clips, as according to prophesy. Here I am repeating the fix that I did on the '99. A couple holes drilled through the two pieces.


Here it is screwed together and I'm pointing to the broken clip.


I took it for a spin, for the first time in a couple weeks. It sort of seems quieter with the redone doors, but I am also missing the headliner. Joann fabrics is closed so that project is on hold. I can definitely hear the front bearings now.
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File Type: jpg IMG_20200404_164156569.jpg (50.8 KB, 70 views)
File Type: jpg IMG_20200404_164358491.jpg (63.1 KB, 69 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 04-14-2020, 09:15 AM   #238
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

I've now owned this $500 car for two years. Would like to start driving it again.
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 04-30-2020, 10:42 PM   #239
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

I started redoing my headliner with a layer of felt.
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...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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Old 05-01-2020, 12:44 AM   #240
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1999 SL2
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Default Re: 98 SC2 project. Drive for now, maybe rebuild later.

I'm on rattle patrol. I popped off the dash. Prior owner had busted the two clips behind the instruments. I'm thinking the easiest fix is to get a dash from LKQ. Will any Gen 2 fit? What about Gen 3?


This thing was torn and hanging down on the passenger side. Any advice?
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File Type: jpg IMG_20200430_224301930.jpg (59.8 KB, 52 views)
File Type: jpg IMG_20200430_224727596.jpg (57.0 KB, 49 views)
...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018
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