My Maruti 800 Carb (1991): Now Restored!

[ss80]

Hi Everyone,

Thank you so much for all the support & motivation you all gave me in my other thread (about restoration as a business).

Why Car?
http://www.theautomotiveindia.com/forums/automotive-answers/12953-starting-used-car-restoration-business-suggestions-invited-1.html
The above link answers it.

Why this M800?
I am tired of meeting people pretending to sell cars. I wasted almost a fortnight hunting for the right car. Little later, I understood that getting a car with this wishlist means lots of waiting & hunting period.

*Untouched Chassy
*Minimal rusting
*Single owner
*Somewhat good condition

After thinking a lot, I had to choose this car keeping aside its negatives..Details later...

Let the pictures flow








The gas tank


Interiors (Art leather - dirty like hell seat covers but good sponge though)




The place where I guess a lot of my time will be spent




Underbody (Jarpickle yes you were right, oil leaks)





Purchase Details:
Car: Maruti 800 Standard (NON AC)
Model: 1991
Owners: 6 owners so far (I will be the seventh)
Fuel type: Petrol & LPG (LAVOTA - Not endorsed in RC book though)

Quoted price by owner: 50,000/-
Bought for: 40,000/-
Paid so far: 38,000/- (2k due)


Good things about the car:
Tyre Condition: 165/70 R12 - HANKOOK
All 5 rims are from Type2 800 & are in excellent condition
Although NOT A BRANDED ICE, still it has USB & CD Player! a USP while selling
Although dirty, the seat covers & sponges seem to be better than most cars I saw
Full outer body repaint done (Engine bay partially painted & floor untouched)
Suspension work done by previous owner 1 year ago
Rear Leaf spring is doubled so its stiff & at the same time better than the single ones
It already had 6 owners! & when I sell I can pitch for my restoration work as a USP as this car definately needs it.
Body line: 7/10

The bombs:
All glasses are replaced (not even a single glass is OEM)
Interiors: 5/10
Brakes: No booster
Wiring has taken a lot of joints etc horrible state to work with
Dynamo about to give up, Battery half dead already
Steering column rattles a lot
Clutch Cable & Throttle cable are hard & squeaky
One tear/scratch in left side wheel well chassy (The only thing I regret about)
No Carpet! No floor mat! No dikki mat! No Jack & wheel spanner!
Rear seat screwed to the sidewall & hence no folding options

Documentation issues:
RC book is a DRC (Duplicate RC Book)
Insurance Expired
FC lapsed in 2011



More to come soon.. (actually in next ten mins)

 

[ss80]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics uploaded)

I enquired about the documentation part with a local driving school here & this is the quote I got

Fitness Certificate - 2000/-
Name Transfer - 1400/-
Insurance - Approx 1400! (for a third party insurance!) they referred someone else for that

Are these above charges ok?

Now back to the caaaaar..
Took the car to my office straight as soon as I bought it from the previous owner, I felt the dynamo was starting to trouble & the fuel economy was scary. For about 40kms that I travelled (to & fro office) it gulped 300Rs petrol apart from what was already there in the tank!

"Mileage is the last thing I should be worried about" - I said this line to myself a couple of times & moved on. While returning from office it was early morning 4am & the headlights (100/90 with relay) lit up the battery symbol on the dashboard. Once I stopped the car for a small break & teh car doesnot start! left it as it is for about 30mins & came back tried again it started, drove all the way to home without stopping anywhere.

Today I took out the car & filled just about 200/- & drove for some 25kms, tank is almost empty again! Drove it through rain & shine, spent a few hours easily with the new darling & came home quite late (also had a breakdown in between)

The first big shock to me was the extent of rain water seapage into the cabin, see the video the source is the same corner I had in my last car! May be 800's have this issue in common after 20yrs or so.

Maruti 800 Restoration - Rain water leakage through windhsield - YouTube







The First Breakdown (Lucky though)
I had the first breakdown with this car due to the weak dynamo issue at the same place where I had a breakdown in my first car. But luckily this time I just reached a parking lot near M.G.Road when the car gave up (while reversing), had it given up on the road, it would have been a nightmare for me.

Since replacing battery was in my restoration plan, I went ahead called Justdial & got calls from a few local battery dealers, spoke to 2dealers & agreed to one of them. They offered a free visit & spot installation of new battery in exchange with old one.

Battery: Exide Champion
35Amps
One year warranty
Total cost to my pocket (after exchange): Rs.2500/-

Thanked the field boy for having come on time & gave a small tip (Rs.100/-), got the battery installed & drove home. I remember one my friend calling MOS (maruti on road service) for a similar reason & he got charged nearly 800/- for just a jump start!

The battery seems to be taking the beating pretty well for time being. I expected this some time week, so I had already removed the speakers & ICE from the car as there was a current leak somewhere (light glows on ICE even after key is taken out).


I hate to see such wires in cars, they are everywhere in this car.




Head Unit will be away for a long time, till everything gets fixed




These speakers are mounted in foorwell & the rear speakers are mounted behind the rear seat!


The front two speakers are out now.

Rain makes the car look more beautiful I guess






Although he did not use/show the lpg mode when I went for test drive, now I know for sure that gas kit works (the owner gave a demo just before parting with it), but since it is not endorsed in RC book, I cant leave it like that when I go for Fitness Certificate examination. Secondly I dont believe that a LPG kit can give good results on a used 20yr old car.

But mainly I hate the slow pickup in the car when on lpg, so it has to go out. I drive very little in a month, so fuel efficiency isnt really the main worry & also I never suggest LPG to anyone who loves driving it (no offense to anyone here, just my opinion)

 

[rayal]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics uploaded)

Your car looks good! I too found it in Olx remembering the painted wheels. The car is lucky, as she came into your hands. ss80, You must be appreciated for your Zeal . I really wondered when I noticed the time of posting, take care. I can say it as bread for a hungry tiger, am i right? I hope lot of worthy discussions and DIYs will rock this thread.

Regarding documentation part, you can bargain.

Me, the first one to post in this thread ha,ha

Once again, wishing nice start of your restoration....

 

[jarpickle]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics uploaded)

The radiator looks aftermarket.

The oil leak looks like it is coming from the gearbox.Hope its not in bad shape.Check the seals and the gearbox breather tube.

As for performance, try servicing the carb.Try the MPI kit this time.

 

[Shantanu.lko]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics uploaded)

Congratulations on the purchase and all the best for the partial restoration.
The mileage issue will be sorted out as soon as you service the car.
BTW, Is the LPG kit LAVOTA or LOVATO. And can a LPG kit be endorsed on a 91 model car.
The paint job is also looking nice.

 

[Indian_Mustang]

Hi ,Anand Bhai.,.
Car looks Awesome and great Build Quality. Special like the Color and the great Deal Also give you some suggestion for the ur “Blue Shark”,
Suggestion for Interior And Exterior
1) Both Bumper Need T o alignment
2) Taillight and headlight clean to inner way .change the bulbs if needed
3) Seat cover needs to clean
4) Floor mate (Rubber mate its cheap and Non -Slip)
5) Engine Bay cleaning special Maruti Chassis plate and wiring (Interior and Exterior) need works.
6) remove the Sunflims or install New one.



Mechanical Line
1) Leakage of oil as u mention may be oil seal is break check the break fluid
2) Check the All wheels Bearing
3) Rust Of car inner and outer. As specially Rain water leakage through windshield
4) Must Thing to Do
Radiator Cleaning
Fuel Injection Line Clean .May Be carbon in lines it’s on GAS .so must To Do (because of u Breakdowns 2-4 Times as U mentioned)
5) Wheel Alignments and Balancing


Its is just Mine Suggestion If u want to Do..thanks we need more and more pic and update best of luck all over ur upcoming car restore work

Some More Suggestion I Forget :P

General servicing
Engine oil and oil filter change
Gear oil change
Brake oil bleeding
Flushed all water from container and poured coolant
Wiper blade change (If needed)
New floor mats
Gear lever boot, housing, gear kit and gear knob changed.

For Legal things to Do

New Smart card RC. (it Add Value on Car .)
Insurance

 

[ss80]

basic checks

Some LPG kit part (no idea what it is)


This is the way the lpg enters carb


Air filter is dirty too


Gave the car a clean bath








The car looks like this without the wheel caps


Removed the tints on all the glasses, the rear ones came off neat, thefront ones were difficult & make a lot noise.






Battery tray


The old battery (now gone)


& more pics to come soon...

 

[Varun560061]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics uploaded)

Wow Wow Wow.. So many pic's..

Car looks neat from out side. Thankfully engine bay is partially painted. I guess it is mechanically good too, other wise just swap the engine which you were rebuilding !

Get rid of those wheel caps, the type 2 rims looks cool on the car, just get the OE hub caps will look classy (10 rs each).

I have got 2 sets of woolen mats (1 for you). Get rid of the big drum at the rear (Ha ha the gas tank).

Use normal shampoo solution to clean the seats, do that asap.

Is that 165 /70 I really don't think so, 70 profile would scrap at rear. Are there two leafs at rear ? (Stock is one leaf).

Get type 2 wiper arms & blades.

Do keep us updated..

 

[ss80]

The first upgrade - Dynamo

Thank you everybody, I am reading your inputs & keeping a seperate note for the same (on my desktop).

Ok now there seems to be two issues which need immediate attention.
Power leak (in some wire) & then the dynamo replacement. Today morning the car did not start at all (multiple crank no use). Which basically means I got to get rid of all non-oem wires in the car & also change the dynamo. I know a person selling his 2month old type1 dynamo (TVS Lucas) for about 2000/- but then I wanted something extra in the car when compared to normal cars & moreover 35amps just wont be enough for the car with 100/90 lamps, wipers, ICE & horns.

Removed the Dynamo & took it to the Gujri where I swapped it for a Wagon R alternator - 60Amps the total cost after exchange came to about 1800/-. He did a small test to see if dynamo works (which was too stupid to do & to be seen).
Came home & here is the first shock - the mount wont fit

So now its time to grind either the mount/ the mounting point on the dynamo. Pics will say the rest...

The early morning mess


The old dynamo going out




The replacement piece - Wagon R (old one - 4 cylinder model) dynamo






The important rear part


While I exchanged the dynamo, I got back the pulley as the pulley wont match ...


The connector part (socket )


I will post the description sticker on it soon...I am planning to clean the alternator, but not sure if I should open it up & dip the outer aluminium case in thinner? Is it easy to assemble it back?

 

[ss80]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Just about to start taking off the LPG kit from the car, will post pics of the same too.

 

[ss80]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Progress in last 3 hours...

Stripping begins
removed all wires related to Gas kit
removed 100/90 wiring kit & extra horn (for FC clearance)
still working on removing the gas line & the tank
removed the wiper tank & coolant reservoir
planning to get rid of the non-oem (I guess so) radiator & front metal piece


Here is a blurred pic (will post a better one soon) of the dynamo specs, sent it for grinding today


The mess in engine bay with the LPG kit installed






The gas kit makes its way out slowly, revealing more holes in chassy!







All of the kit is here on the floor now (Shantanu here is a close up of the item name)

 

[dharmesh]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Wow . I am glued to this thread. Congratz for your new acquisition and I am sure it has come to right hands.

 

[ss80]

Slow progress....

I dint know that coolant will rerouted towards the lpg thing (dono its name) its leaking now.
View attachment 98197

View attachment 98198

The gas line that will removed soon & all the holes to be tinkered..
View attachment 98193

View attachment 98194

The whole kit in the bag now..
View attachment 98195

Here is the radiator that should be replaced soon
View attachment 98199

 

[ss80]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Drained the two plastic tanks (wiper & coolant) & kept them aside




The empty space after the two containers are out..







The stock wiring is somewhat in scrap shape, I am yet to decide about this though. For time being car is a store house for itself, till I find someone who lend his car park/garage for me work in.



The last update for today...

Dharmesh: Thank you for the support sir.

 

[lucky_skyline2002]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Woaahh thats a one cute wheels I am looking forward to...!!!!!!