My Maruti 800 Carb (1991): Now Restored!

[ss80]

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

Thanks Vaibhav, I dint realise the issue with brake hose and drive shaft boot, till I replaced the lower arm. Probably next weekly off is going to be dedicated for drive shaft boot. There is gear oil leaking from the spot where the drive shafts meet the gearbox, not sure whats wrong. This will be the real DIY challenge, trying to fix the drive shaft boots.

 

[ss80]

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

Lot of progress this monday
Renewed 3rd party insurance, emission test done, brakes inspected at garage, got all drive shaft boots changed, wheel alignment done, Varun is getting the WagonR dynamo rebuilt and will be fixed within a week :D

 

[rajan007]

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

hello bikeranand and varun

i am new to tai and pleased to watch this thread

i too bought a maruti 800 ac 1996 model

condition is about good :P

i too now wants to restore after this thread

but dunno how to start :S

help me to fix its indicators (Y)

 

[ss80]

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

Hi Rajan,
glad to know you that you also have a Type 1. Check all bulbs and fuses if not connections of indicators to the main wiring, that should help. Start a ownership thread and post pics, we will surely give all info we have to help you.

Update:
Finally the 60Amps alty is ready, with new windings, new pulley and fixed in the car :D

Brighter headlamps= yes
battery charging = yes
smoother idling = yes

few pending works, with regards to the alty = the belt is not aligned properly due pulleys not being in straight line, so I have to cut and modify the mount to suit it, needs a bit more time. Postponed it till the current belt gives up. Few pics. Also the heavy duty wire is yet to be installed.





This gap will also increase once the alty mount is modified


New connectors as old ones got cut

 

[Varun560061]

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

Cool ! In my car I have totally grinded off the nuts on the mount. I have used a long bolt to secure the alty. Also you can bend the top mount so that the alignment is perfect.

 

[rajan007]

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

Hi Rajan,
glad to know you that you also have a Type 1. Check all bulbs and fuses if not connections of indicators to the main wiring, that should help. Start a ownership thread and post pics, we will surely give all info we have to help you.

hey Anand

soon i start thread too

 

[ss80]

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

The alty belt is not aligned properly with the rest of the pulleys, hence to rectify this I did a lot of jugaad and got the top mount slightly bent, that is again faulty and hence both top and bottom mounts needs to be cut and rewelded so that the dynamo sits about 1/2 inch towards the Right side headlamp. Welding shops near by home are reluctant to do any such mods, as they are too lazy. Have dismantled everything and tomorrow morning I will have to try with a different welder.

 

[ss80]

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

Finally the mount cut and welded pushing the alty towards the RH headlight. Success .






Painted the welded area with cotton waste and some old black paint, just to avoid rusting etc


Also the gap between oil filter and alty is now better,



alignment of belt is 95% (slight variation still left. Will deal with it in the future. Belt needs to be a bit shorter one now sa tension is less as the alty sits closer to pulleys.





Final thing left is to fix a fuel leak from return hose of carb, tried different size pipes, clamps all of no use.


Will do something about it tomorrow.

 

[ss80]

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

Fuel leak in car - YouTube

 

[ss80]

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

After wasting about 200 rupees finally a shop keeper helped me out by giving the right pipe (MPFI fuel pipe) and fel leak is solved.
.

Reverse gear switch wires have come out of the switch, no point in repairing these, so just bought a replacement one, yet to fix it.

 

[ss80]

Repainting begins :D

After a lot of thinking, finally I have decided to change the colour of the car, I painted one fender in Orange and one fender in Metallic Grey, both seemed to be too extreme. Finally the colour is BLACK!

So started off today ripping entire engine bay and bundling wires and covering them up in cloth. Took special care for the new carb though. Used body filler in places to cover the old LPG kit holes etc and also near the rusted battery tray,I used a PU paint with a bit more hardener and here is the result.

















The front area covered with newspaper just to avoid dust on the wet surface, as I have done the painting outside my house.

 

[Varun560061]

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

Nice work SS80 !! Where are the cables, wires etc. Engine bay looks empty.
Make sure you paint the battery tray it gets rusted soon.

Do we need to apply clear coat on the inner surface too ? Whats the reaction of your neighbors ?

Waiting for the end product !! A shiny blacky 800..

 

[sumitsinha12]

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

Great Progress Anand.
Nice color choice. Which brand paint are you using?
Waiting for finished shining 800.
Good luck

 

[adil3996]

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

hey Anand plz do remove those Bonnet Adjustment Rubbers and spray the final Coat..
B'coz after some time the surface around the rubber starts cracking and peales off

 

[ramankanythia]

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

wahoo that what i was waiting for

r u using brush for engine bay or spay paint