Khyber 91's Second Reincarnation

[Deadly_Flame]

Aoa Everyone,

I am going for a rebuild again for my car. It's a daily driver. I am aiming to get good bodywork done this time around. Would love to have input from you guys. In sha Allah, mil jul ker with your guidance, hopefully can have a good/durable outcome in this second round.

About the Car
So this is a 91 model Khyber, we've had it since 2001. It has a G15A under the hood since 2014, totally stock with a desi Simota air filter. The car is adequately quick. Interior is below average atm, might do some work on it, depends on how much the restoration costs.

Location
I am based in Pindi/Isb so if anyone has suggestions for good denters and painters, please do share.

Target
For now it is just to get some good body work done because the gadri area is weak and since it has a stronger engine, the body needs to hold up. I am also looking for a good paint job this time around, last time the paint work was not good enough, lots of poutine work. The undercarriage will need special attention, will really like input from the enthusiasts to help out.

Disclaimer: The car is not in a very good condition. I cannot sell the car as I don't have enough money to get a new one. Maybe I can get a good car if I sell it and add 2-3 lacs on it, but it won't have the power that I need and I'll have to put in another 50-100k to fix the minor things. So selling is not an option, have to get this one fixed.

Looking forward to your suggestion and feedback.

[Deadly_Flame]

So I've got the car inspected from two denters as of yet. One of them did the body work last time around, he has quoted PKR 35k as labor cost. The second one is Car Garage near Bahria Phase 1-4 and they've quoted PKR 40.
I am hoping to avoid as much poutine work as possible. Car Garage says that floors are fine, just need to clean up and put namda on it and good to go. Also, how do I reinforce the structure around gadri and mounts or better yet what reinforcement should I consider?

Current state of the under carriage:

[Xulfiqar]

Whoever told you those floors are fine needs an appointment with an optician.

[Hassan1991]

Wailaikum Assalam
Now that floor looks similar to my car.
No it's not fine. Aspect tons of rust between the layers of metal as denters weld new sheet on rusted metal.
For reinforcement you need to add tie and strut bar.

[saad2006]

Good luck with this project, another khyber getting the attention it deserves

[brownrose78]

@Hassan1991 make diagram for chassis reinforcement whether it is strut bar or tie or whatever suggestions you have.
1 of my car is also having worst flooring than this

@saad2006 is right and I think @Mustansir posts and thread can give Starting path

[Hassan1991]

Sure. Share some pictures of bay without engine i can give rough idea.
Tie bar should be something like this one.
i made it 2 years back for my car.
Ignore my poor tig welds.
Size 1.25" 12 gauge tube.

[brownrose78]

Do you have post installation pictures @hassan1991

[Hassan1991]

Didn't shared yet except this one.

This is how pipes should be connected. Change the valve as it would be choked with dust. (Ignore the length of pipes) [image]

[Xulfiqar]

What the hell is going on with the brake tubing? Spider made them?

[Hassan1991]

Haha, long ones were fitted. They are gone now.

[Deadly_Flame]

Whoever told you those floors are fine needs an appointment with an optician.

Noted, new floors it is then

No it's not fine. Expect tons of rust between the layers of metal as denters weld new sheet on rusted metal.

So I'll go for new floors, are there any qualities of flooring for khyber? What gauge should I opt for? Or are they all similar and I should simply get the ones available. A desi strut and tie bar is installed, the tie bar is not as intricate as the one you shared. I don't have a picture for the tie bar, will take one when I get back.

posts and thread can give Starting path

Yes, I've gone through his thread. Have some questions that I'll ask when I get to those particular stages. Right now, need to find a good denter or at least someone who will be receptive to my feedback.

1 of my car is also having worst flooring than this

Dayum

[Deadly_Flame]

@Hassan1991 This portion seems like the firewall area, looks rusted to me. What can be done for this area?

[Hassan1991]

Get 16 gauge (~1.63mm) floor metal. Pressed in same shape as khyber.
First clean that piece using any rust remover, chemical or wire brush.
I looks like it already being repaired.
You need to rip all those pieces and weld a single piece. So it can be painted from both sides.

[omaruser156370259465]

Does strut bar have any disadvantage?

[Deadly_Flame]

No to the strut bar, for tie bar in my case yes. The tie bar is a little extended below the engine so if there is some high bump in the middle of the road I cannot drive above it, I have to move the car to avoid it, speed breakers are fine though.

[Hassan1991]

Actually it does.
Without proper mounting plate any reinforcement bar will broke oem spot welds.

[Xulfiqar]

Yep, used to love seeing people make copies of such bars from gate wala and then a year later ask, why is my car broken?

[Deadly_Flame]

Without proper mounting plate any reinforcement bar will broke oem spot welds.

This is the desi strut bar that's installed, can you point out as to which OEM spot welds are susceptible to breakage?

The tie bar is something like this It used to be straight but some heavy scrapes and this is how it looks now, probably of no use in this state. Will look into getting something similar to what you showed. This pic reflects a little more clearly on the rust situation underneath.

[Hassan1991]

Struts looks fine. Is that a solid bar or tube?
If you look at khyber's front struts design they are a part of firewall that gives little extra strength to them.
Move the flexible pipe back a bit, will give you more room for tie bar.
Floor does look like my car.
You need to do some serious cutting. Do measure everything before that.