CME on Saab 9-7x Aero - First Time Welding
01-04-2011, 08:39 PM
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CME on Saab 9-7x Aero - First Time Welding So I've been wanting to do a custom center mount exhaust setup on my Saab like I had on my old Envoy. Instead of spending $500 to get it done, I decided to buy a MIG welder, a miter saw, and some tubing to do it my self. I have never welded before so I read a book, read the owners manual, and started to make a couple of practice welds with two small 3" tubes. I am going to install my Pacesetter long tube headers and Y-pipe at the same time with the CME. I dropped off the headers at Enduro Coatings in Mesquite, TX to get them ceramic coated. Just wanted to share some pics/info as I work on this project...
The rear bumper cover already has a nice valance with a cut-out for the hitch receiver. I'm just going to have a body shop fill in/smooth out the cut-out for the stock muffler tip and the trailer wiring harness. While I'm at it, I want to get all the lower rocker panels paint matched.
First I took the rear bumper off and cut the center of the hitch receiver out. I didn't want to cut all of it out since there are some small brackets welded to the hitch for the bumper cover. This piece weighs 15 lbs...
For my first welds, I welded some flat plates to the open support bracket so it wont look too ugly from the outside. I didn't have anything to cut them with at the time so i just welded them on as is. I still have to cut off the trim areas and smooth the edges out. Also gonna spray some rustoleum on the bumper once I'm done...
I found some exhaust flanges at a local circle track parts shop and welded them to the headers. These flanges are the 5th and 6th welds I've made so far and I still think they look better than what most local muffler shops do
I used (2) 45 degree 3" mandrel bends to make a "y-pipe" for the exhaust tips since I will be using a 3" single inlet/outlet magnaflow muffler (which is already installed on my Saab). Wasn't easy and didn't come out pretty but will work fine...
I cut the trim on the plates for the support bar, smoothed it out some, and painted it black...
I held the tips on with a jack stand and took a pic of how they will look from the top...
Its a 120v Lincoln Electric WeldPak 140HD and a 75/25 Argon/CO2 gas mix. I used the .025" wire that came with the kit. I have to be honest, I was so nervous using the welder and the miter saw that I was sweating like a ****. The miter saw isn't really meant for cutting steel but I put a cutoff disk on it and was well protected. Both will come in handy in the future tho. I bought them for myself on Christmas
More to come! My Saab is at Phoenix Transmissions in Weatherford, TX right now. They are borrowing it for the week to test fit a 4L80E with an adapter for AWD. Once I get it back I should have my headers by then and keep on working on it.
The rear bumper cover already has a nice valance with a cut-out for the hitch receiver. I'm just going to have a body shop fill in/smooth out the cut-out for the stock muffler tip and the trailer wiring harness. While I'm at it, I want to get all the lower rocker panels paint matched.
First I took the rear bumper off and cut the center of the hitch receiver out. I didn't want to cut all of it out since there are some small brackets welded to the hitch for the bumper cover. This piece weighs 15 lbs...
For my first welds, I welded some flat plates to the open support bracket so it wont look too ugly from the outside. I didn't have anything to cut them with at the time so i just welded them on as is. I still have to cut off the trim areas and smooth the edges out. Also gonna spray some rustoleum on the bumper once I'm done...
I found some exhaust flanges at a local circle track parts shop and welded them to the headers. These flanges are the 5th and 6th welds I've made so far and I still think they look better than what most local muffler shops do
I used (2) 45 degree 3" mandrel bends to make a "y-pipe" for the exhaust tips since I will be using a 3" single inlet/outlet magnaflow muffler (which is already installed on my Saab). Wasn't easy and didn't come out pretty but will work fine...
I cut the trim on the plates for the support bar, smoothed it out some, and painted it black...
I held the tips on with a jack stand and took a pic of how they will look from the top...
Its a 120v Lincoln Electric WeldPak 140HD and a 75/25 Argon/CO2 gas mix. I used the .025" wire that came with the kit. I have to be honest, I was so nervous using the welder and the miter saw that I was sweating like a ****. The miter saw isn't really meant for cutting steel but I put a cutoff disk on it and was well protected. Both will come in handy in the future tho. I bought them for myself on Christmas
More to come! My Saab is at Phoenix Transmissions in Weatherford, TX right now. They are borrowing it for the week to test fit a 4L80E with an adapter for AWD. Once I get it back I should have my headers by then and keep on working on it.
01-04-2011, 08:53 PM
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Nice work! I've been wanting the opportunity to some virgin welding myself, but need to get another ride first. This gives me confidence though that I can do it. Good luck with the the finish!
01-04-2011, 09:41 PM
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01-04-2011, 09:53 PM
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No man, don't you see my sig? It's just a 6................liter 
Gotta have a steady hand and patience. Eventually I SHOULD get good at it
ready when you are
Actually they are just going to borrow it to test fit one in there. I don't have the money for the swap. They offered a free stall converter to whom ever let them borrow an AWD TBSS. No one replied for a few days so I went for it since my converter isnt locking up. They offered to open mine up to repair or replace it and freshen up my trans. It's a win, win. 
ready when you are
01-04-2011, 09:54 PM
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http://cgi.ebay.com/ebaymotors/Pypes...item483e0ed8cb
They have a 3" inlet and also offer a 2.5" inlet.
They have a 3" inlet and also offer a 2.5" inlet.
01-04-2011, 10:03 PM
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These were overpriced at $50k for the Aero while the TBSS was $40k. They are very rare. I bought mine for $25,000 ($27,000 including taxes + fees) thru CarMax. Fully loaded minus rain sensing wipers and headlamp washers (better without them), Carbon Flash Met. w/Ebony interior, 27K miles, 50k/100k GM warranty. At the time it was the best deal I could find. It was actually out in Florida but had it shipped to Garland. The rest were selling for $28-30k up North. I like it cause its different. Everyone always hates on it cause its not a TBSS. 
01-04-2011, 10:08 PM
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I will once I get it back. I just did this last week and over the weekend. I put the bumper and bumper cover Sunday evening and took it to Phoenix yesterday morning. The rear bumper is primer cause I had it repaired after someone put a dent in it while I was parked at work like a week after I bought it. 
http://www.tbssowners.com/forums/showthread.php?t=45475
Damn I miss seeing paint on the rear bumper lol But i've been waiting to do this CME mod before I get it painted. Soon.
http://www.tbssowners.com/forums/showthread.php?t=45475
Damn I miss seeing paint on the rear bumper lol But i've been waiting to do this CME mod before I get it painted. Soon.
01-04-2011, 10:08 PM
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These were overpriced at $50k for the Aero while the TBSS was $40k. They are very rare. I bought mine for $25,000 ($27,000 including taxes + fees) thru CarMax. Fully loaded minus rain sensing wipers and headlamp washers (better without them), Carbon Flash Met. w/Ebony interior, 27K miles, 50k/100k GM warranty. At the time it was the best deal I could find. It was actually out in Florida but had it shipped to Garland. The rest were selling for $28-30k up North. I like it cause its different. Everyone always hates on it cause its not a TBSS.
talk about a sleeper.
01-04-2011, 10:12 PM
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http://www.youtube.com/user/Dirty30LS1
01-04-2011, 10:50 PM
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Yeah it's fun for being a heavy bitch and with my heavy *** in it. I have a bunch of vids on youtube http://www.youtube.com/user/Dirty30LS1
http://www.youtube.com/user/Dirty30LS1it looks like matamoros high way
