Bought My First Car - Maruti 800 AC

[samsag12]

Here are the pictures of the mat. Guys please do suggest if I should add some thick soft cloth too, so that noise cancellation is more. Otherwise I would not be able to enjoy my new ICE, if the engine is roaring inside the cabin

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Thickness of the mat
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The sheet looks thick enough to give you nightmare while fixing, but i am sure you'll figure it out.
For insulation try using 25kilo jute bags of rice (bora in local lingo). Use 2 of them, place it in between the firewall & this rubberised sheet. Have experimented this on my older cars, works to quite an extent.

 

[ss80]

Interiors ripped apart, now firewall DIY starts

The sheet looks thick enough to give you nightmare while fixing, but i am sure you'll figure it out.
For insulation try using 25kilo jute bags of rice (bora in local lingo). Use 2 of them, place it in between the firewall & this rubberised sheet. Have experimented this on my older cars, works to quite an extent.

Yes it will trouble me a lot, as it is thick, wont flex much.
Well this is what I have in mind, I will cut the sheet with curves of the sides so that it just matches the wheel arches, holes in the middle for the blower bolts, steering column etc.

Pic is not that clear, just to give an idea I have put it here.

If you are adding it to the firewall, make sure it can handle the heat.Else it will melt off.

This is something which is really making me worry very much. I though Yoga mats will be placed in between the firewall & rubber mat. But seeing your post, I dont think Yoga mat will last even a day

Okay so either now Jutebags or may be someother material I will think of. Can you suggest me some more ideas for this, as I want to fix this thing ASAP.

Will applying 3M Underseal help in anyway? I know that it is applied outside the car, but since it has rubber or tar elements (I guess so) in it, I thought it might help if applied on Firewall & floor interiors (below carpet area).

Update:
Painted the A pillars today with a "F1 chrome spray" just wanted to hide those tinker works done previously (a month back) I am working on a DIY plastic trim for the A pillar so that this paint is not visible.


Covered both sides of windhshield to avoid the paint smoke getting in contact with it.

 

[loner]

5. What about the roof, i mean the stock roof comes in grey color, what would you suggest to make that match the beige interiors

The roof i feel is the biggest challenge i will face in my esteem when i change to the beige interiors because having a grey roof and all beige interior will really look bad. And to top it mine is the felt type

You can use the same colour fabric paint and paint with a brush with fine bristles.

@ss80: Does the chrome paint really look like chrome. why did'nt you paint that area with the blue paint you had painter the floors.

 

[ss80]

It looks like dull silver, I dont have any of that blue paint now & to get that sample I have to take the fuel lid cap/some other blue part of my car to the paintshop. So that he matches and gives me the paint. Secondly the paint that I get for cars has to be sprayed using a gun & that means again hiring a compressor now. TOday & tomorrow are Bandh and that compressor rent shop is also closed till monday. So decided to use whatever spray I had to save time.

I have the old B pillar plastic trim in grey colour. I will try to use that and cover up this paint job neatly.

 

[loner]

Have you thought about using the roof felt material and trim it to shape the a,b,c pillars? one of my colleages made it for his maruti zen since he found lots of this material at scrap bazar. Could you tell me what the mixing ratio should be for paint to thinner and clear paint to thinner?

 

[ss80]

We usually use the PU paints for automobiles, this needs to be mixed with PU Thinner (not the ordinary thinner a.k.a NC thinner) & Hardener. I used this ratio 200ml paint + 100ml thinner + 40ml hardener. However you can play with this ratio to increase or decrease the liquidity (aka viscosity) of the paint mixture.

If you mix too little thinner, the paint wont spray & it will come out like hair from the gun tip. If you mix thinner too much, the paint will not stick to the surface, it will just leak in drops from the surface. Too much hardener, again the spray will be like dots & rough finishing. Too little hardener, no issues for now, but will take long time to dry & secondly colour starts to fade within few days of exposure to sunlight.

1 : 0.5 :0.25
Paint: Thinner: Hardener

There is no hard and fast rule in mixing paints while spraying. Just know the basics, you might waste a little in the beginning but that's alright we all do. Note: Do not do any mixing in the gun tank, mix the paint seperately & pour into the gun.

 

[ss80]

DIY Damping of firewall completed:

Let the photos do the talking :D

1. Stripped the interiors fully


2. Stuck papers to the firewall using masking tape & traced (cut) out the shape I wanted


3. Placed the paper trace on the rubber sheet & cut the rubber sheet accordingly


4. This thick rubber wont bend much so I had to leave the wheel arch as it is


5. Thanks to the newspaper method, I could leave space exactly for the blower mounts & some hooks already used in previous factory damper cloth







6. The rubber sheet has cuts at the bottom part where the exhaust tunnel starts


7. Hole for the steering thing to fit


8. This area I did not explore much as the brake pedal etc comes here & I do not want to spoil any of them


9. Time to check if everything is alright


10. One layer of Yoga mat to protect the rubber sheet from heat & also the yoga mat is sort of water proof. The rice bag idea is risky as 800 has too many holes on FIrewall any water leakage will be soaked in the rags & rust might start.


11. Completed sticking






12. Finally applied SR adhesive on both surfaces & left them to dry for a couple of seconds before placing them.

 

[RPM2500]

You can use the same colour fabric paint and paint with a brush with fine bristles.

Yes i have been thinking of doing this, but the concern is the cloth might expand thereby leaving bumps on the surface, However after reading your post i faintly remember a customer at the paint shop leaving his old felt roof after he replaced it at the paint shop. I can try that on that roof , see the finish and then do it on my car

 

[Varun560061]

Fitting looks good. Hope blower and dash fits without any gaps.

What I fell is, may be you need to cut the rubber near the blower mounting points so that blower fits properly.

Do post pic's after blower installation.

 

[ss80]

Its just drizzling here now so had to adjourn today's work
However tomorrow the Blower, roof, dashboard etc will be fit & I will watch out for that blower mounting points.

Started the car & yes there is a difference in the engine noise inside the cabin. Once the roof & floor mats are put it should reduce further. Previously the noise was too much to live with, now its better. (But it isnt that silent like say a Mpfi 800 or Beat or i10 etc, but better than the past few experiences.

 

[jarpickle]

I would have done it in reverse.The black foam side to the firewall and yoga mat outside.You do get heat resistant paint from bosny.Not sure how it will help though.The underbody coating is good in case of leaks and stuff.Instead you can try 3M Antirust.One of its benefits is sound deadening too.
http://solutions.3mindia.co.in/wps/portal/3M/en_IN/CarDetailingServices/Underbody/Anti+Corrosion/

 

[ss80]

Speedometer cable changed + blower mounted

I would have done it in reverse.The black foam side to the firewall and yoga mat outside.You do get heat resistant paint from bosny.Not sure how it will help though.The underbody coating is good in case of leaks and stuff.Instead you can try 3M Antirust.One of its benefits is sound deadening too.
Anti Corrosion & Rust Protection Treatments

My fear was that the rubber might melt or stink the cabin due to hot surface of firewall. So I did it this way, hope my guess works out. I think that Bosny paint (heat resistant one) might be too costly, so I skipped that part.

This might sound silly but still, but I am asking again here. I know that 3M antirust is applied outside the car, but since it has rubber or tar elements (I guess so) in it, I thought it might help in damping if applied on floor interiors (below carpet area).

Can this be a DIY? How to apply that liquid on to the floor? Brush or spray gun or some seperate tool?

Updates:
Made a few holes for the blower unit to fit precisely on the firewall.

Work in progress

I have just fit the dashboard today, couldnt take pics as I was exhausted. Will post tomorrow.

Also today I changed the speedometer cable in my car.

The old cables point (connecting part)

The new cable

The speedometer cable's one end fits the gearbox & there is a 10size bolt which needs to be losened to pull out the cable. Here is a pic of that.

 

[jarpickle]

Yeah, you can apply it on the inside.Spraying it is a better option.But I believe you can use a brush,just keep in mind the time it takes to dry into account.

 

[ss80]

roof installed, central locking almost complete

Yeah, you can apply it on the inside.Spraying it is a better option.But I believe you can use a brush,just keep in mind the time it takes to dry into account.

Thanks for clearing my doubt, I guess I will do it in a weeks time. Will one full day in hot baking sun be enough for the anti rust to dry? or should I give it a couple of days? Will the roof absorb any smell from this thing while drying?

Update:

Central locking almost installed, roof fixed firmly.




In this moulded roof the rear end has holes for the buttons to be fixed. My problem is my car has no holes over there & I am worried if drilling will reduce the strength of my aging car. Will the side roof hanles & sun visor points be enough to keep in place without loosing shape?

 

[Varun560061]

The mounting would be enough, but the empty holes will give a odd look. Don't worry go ahead and drill holes.