My Maruti 800 Carb (1991): Now Restored!

[ss80]

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

Raman: I too am hoping for the same.

Sethu Sir: Thank you sir, I will make it a point to drive to Chennai and meet the Sparky once the car is in drivable condition. TAI and its members support and feedback is like the fuel for all my work.




grill fixed



Doubts about the steering rattle:
Each time the front wheel goes over any pothole/rough hump, there is kat-kat noise and shuddering from the steering wheel (only steering wheel and connected parts), it is not a suspension related thing for sure. However how do I know if it is the Steering box in engine bay? or Steering column/its bearings? or what exactly has gone wrong?

 

[Varun560061]

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

The only cause for this sound is the steering coloum or the steering rack.

I got the steering rack changed recently but this sound is still there, now its from the star joint in the coloum. Try to move the steering when the car is parked and see if you find any play then its the star joint.

 

[sumitsinha12]

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

SS80, Congratulations on giving your car a new life. The new carb looks great in the engine bay.
Also the grill looks great on the car. But the front bumper is looking dull infront of the newly painted grill.
How about giving the bumper too a fresh coat of black glossy paint?
Or getting a new bumper?

 

[ss80]

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

I will probably paint the bumper before FC.

Did a temporary fix for the rusting on Apron.

 

[ss80]

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

Shocker for all M800 fans and owners.

MGP and local stores dont have Gear Rod for type1 800! It is available with Essar only on order basis. So I had to finally get the existing gear rod welded to right spec. I bought a local make gear rod bush kit and fixed it as well. Drilled and added a few screws into each door pad so that they are fixed firmly, as the rexin I glued to the door pad was slightly thicker and does not allow for the door pad buttons to fit completely.

A few pics.....











Changed the colour of the wheel caps as one of the wheel caps got scratched. A darker shade this time.

 

[ss80]

Gear issue fixed, wheel cap painted, speedo repair in progress









Tried adding a SMD light buld to the meter board and cut the top portion for better illumination

 

[Varun560061]

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

I dint get what you are doing with the speedo console . Also the placement of the tripod stands should be towards the wheel arches (behind the wheels) as the main chassis is supported and doesn't slip.

You could have used the press clips instead of the screws for the door pads. It would look better.

 

[ss80]

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

I just cleaned the speedo and tried to get better lighting. the chassy is not that good in shape to hold the car at the running board end/joint place.... I am 100% sre when ever I add booster the wheel alignment will go for a toss as well.


I wanted zero rattling noise from the door pads so apat from the stock clips..I drilled small holes and fixed oversize screws (same black colour). No rattling from door or door pads now.

 

[ss80]

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

Tried to fix the meter guage issue.....ended up with a new prob...car is not starting...it cranks, but immediately switches off..

Painted 2 wheels with black so that the wheel caps look good on it. Not able to do the rest of the wheels as car is parked very close to wall and is not starting now...

 

[ss80]

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

A big update, DIY wiring completed.

Replaced only the engine bay cum dashboard wiring in flat two hours. The biggest obstacle is the steering wheel and brake pedal combination, had to remove them and then do the work. There were a few unwanted grounding points in the wiring, some strange slicings to tap power as well. Now all of that is gone. Now just the stalk needs to be changed as the right indicators dont seem to be working. I will check everything once again before changing that.

 

[ss80]

Pedal + steering out


The steering column and the brake pedal assembly out

 

[Varun560061]

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

Does this wiring kit include connection for cabin lamp and the door switches, blower ?
Is the blower speed regulator working now..

You could buy the combination switch from Anupam it will cost you below 400 rs.

 

[ss80]

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

Yeah Varun, the wiring kit includes output to the cabin lamp. Door switches are in the old wiring that stretches from dashboard to tail light. Blower still works only on high speed. I am almost drained out of cash this month so not planning to buy anything till next month. I am still using just water and not even coolant in the radiator.

 

[ss80]

New lower arms + bushes + coolant installed

Yet another weekly off and here I am with another major shopping for essential parts and a good 5hours under the sun diong this DIY. I had this indicator issue on one side so checked everything, so replaced the Stalk/combi-switch...Severe play in front wheel while braking and also horizontal movements during start offs....so changed a few suspension parts...the pics will explain the rest.....




























New probs discovered.

 

[vaibhav.lko]

Re: New lower arms + bushes + coolant installed

great work sir.i think u must replace all the rubber parts of the suspension in one go.its better then doing things one by one.and is your axle fine??And one more thing jst soak all the rubber parts in brake oil before putting them in.it makes them little soft and prevent them from cracking.