Cosmic Aero lives.. again!

The Aero lives once more!

Got her going on Saturday morning. First startup was as nerve-wracking as ever, there was a sound like piston slap but it was probably just the lifters– it's so hard to locate sounds in a motor.. Suffice to say that sound has not returned.

So, finally – I hope this is it.

I replaced the whole balance shaft assembly including the housings, and I replaced rod and main bearings. Thanks once again to @jamesinc for helping me by fabricating the Saab special tool for replacing balance shaft bearings, which performed flawlessly!

I'll drive it 500km or more before I decide all is well, but so far so good. The power is addictive after driving the XC90, especially from 60kpm to 110(-ish) kph..!

I put a couple of hundred km on the car yesterday, it's going very nicely. It also passed its annual registration inspection without any fuss. I was very proud!

Next plans...

I've been waiting to move on to these for sooooo long now!

• Repair minor rear arch damage (quote for paint was $700... ouch!)
• Add the rear spoiler
• Replace tyres on stock Aero wheels with ones i have in the shed
• Change rose bushings in rear suspension, considering buying the eccentric set for proper alignment
• Tint on all the electric windows is knackered, might remove / replace, leaving the quarters and hatch
• Paint correction / dent removal - needs a very good polish!
• Save for downpipe and exhaust upgrade (keeping it fairly quiet with 3" to 2.5")
• Save for injectors & FP
• Save for a tune...

I'll probably go with an off-the-shelf downpipe, but get a custom exhaust made from that back so I can have a bit more control over the sound and tip. This will be a fair way in the future..