AP9engineering

This part started as a problem on my own car.

Original rear hatch trims for the Saab 900 Classic are almost always warped or shrunken — so I developed a proper reproduction to OEM standards.

After testing and installing it myself, I decided to produce a small run.

Saab 900 Classic Hatchback – 3 & 5 door

Available now.
DM for info.

Recreating Saab 900 Carlsson Wheel Arches – A Different Approach

One of the biggest challenges of keeping an older car on the road is finding quality replacement parts, especially when originals are no longer available. That was the case with the wheel arches for my Saab. While there are some great aftermarket options out there that provide affordable solutions, I wanted to take a different approach—one focused on achieving the highest possible accuracy and durability that I can.

The aftermarket wheel arches I previously used were made of polyester resin and fiberglass, which is a common material choice for small-scale production. While it works for many applications, it does have limitations, such as shrinkage, brittleness, and reduced weather resistance. On my car, cracks and blisters developed not long after painting and installation. Instead of trying another set, I eagerly wanted to engineer my own solution.

Finally, just recently, I was able to source brand-new original wheel arches, which allowed me to create precise molds. Using high-heat epoxy and carbon fiber I did just that. From there, I used prepreg carbon fiber and the correct processing methods to recreate these parts with OEM-level accuracy. In addition to the overall shape and curvature even the original part numbers are embedded, and the surface finish is just like the factory parts even though I realise the parts will eventually be sanded and painted over. Still, thanks to the choice of materials and process, these arches maintain their exact shape and exceed OEM durability—handling even extreme temperatures up to 120°C without issue.

For me, these small projects are never just about making replacement parts but also about pushing quality and precision as far as I can.

The same but different. When I started the renovation of my Saab I knew I wanted to do something different with the wheels and update the brakes. Things kept escalating and I ended up here. Custom 17inch wheel from who were very kind and helpful making the changes I requested. Brake calipers and disc from Alcon with some of my own designed cnc hardware and of course some carbon fiber parts which is my personal passion.

Front brakes are starting to take shape. Disc and caliper cooling are the next milestones in this “Saab 900 brakes” subproject that keeps on escalating…