Restoring my Suzuki Khyber 1992 model

[hassan676]

Hello All,

I'm Hassan, a slient member on pakwheels for a long time. I purchased a suzki khyber almost a year back. It was my first car so just fell in love with it. But after sometime passed i realized some rust in the body that alarmed me, so i started thinking of restoring it. Almost 3 months back i contacted a workshop owner (with some reference) who provides denting/painting/mechanical services. So i decided an initial amount with them and left my car at their workshop.
The work started and now after almost 2 months the denting is complete. The following is the detail of denting:

a) Roof and front pillars were totally rusted. So i purchased a desi roof because couldn't find the "Kabli" and i heard the prices for "Kabli" are too high. The denter was a bit reluctant first but i convinced him.

b) Both back fenders with inners (Baghlain).

c) I decided to not change the doors rather just do denting.

d) The floor (Farsh) was comparatively and surprisingly in a good condition with no deep rust. And the previous paint was still in good condition.

e) The engine room had the a major crack near the right "cuppa". So that was welded.

d) All the minor issues (holes, rust) were removed and pieces were patched at the rusted places.

I thought to share the pictures with you and share my journey of restoring this splendid beauty from the good old 90s days.

Now the denting work is completed. And painter will start his work in a day or two. I'd be very thankful and glad for all the comments and suggestions from the Pakwheelers. I'd like to benefit from your worthy advises and input. I will continuously be sharing the pictures on regular basis. By looking at the pictures you will get an idea that what was the condition of the car and the "Desi" samaan that i have opted to go for and the amount of work done. I will soon share the most recent pictures after the denting is completed.

Some Rust in the pillar

The "Desi" Chat

Rust

Old "Roof" removed with front pillars. The middle pillars were in almost genuine condition

The amount of rust in old roof.

Old back fenders and baghlain

It was complete rotten and rusted

Please if you guys can give your feedback and input i'd be really obliged and thankful <3

@omersiddiqui5482 @Xulfiqar @brownrose78 @mustansir44 @Deadly_Flame @capsat @nnabeel

[brownrose78]

@hassan676
Welcome on Board....Nice to see 1 more in the Love of restoration the old beauties. Good Luck to you for this project.

BTW in which city you are located. In which shop, you left the car & the amount decided?

Yes, indeed the amount of rust shown in pictures are enough to raise the Eye brow. As you have written, the work of Denter has been completed, what about rust converter application.
Also go for Oven-Baked paint with some good brand of paint instead of so-called "Japani Paint hoga Sir G"

[omersiddiqui5482]

Oh dear lord that rust is dangerous... @capsat sir need your thoughts is this project viable... @nnabeel Bhai @margallar sir have a look...

[hassan676]

Thankyou @brownrose78 for your kind reply. I hope i can do this project in the best possible way. I am located in Rawalpindi. I left my Khyber at a workshop at a workshop near "Car Chowk" near Safari. The workshop has no name, the owner's name is Saeed. To be honest i don't know what is "Rust Converter Application".
As far as the paint is concerned, they don't have any oven baked paint facility rather i have seen the painter to use Spray gun and heat gun etc. He said he will use 2k paint. The amount of dainter was 35 thousand but now they are saying to give some more amount as it involved a lot of work and the "Desi Parts", the paint amount decided was 40 thousand and it includes complete paint from inside and outside and removing paint from outside using "Raigmaal".
I visit them on daily basis almost..Yesterday painter was saying that he will start "Raigmall" and "Astarr" so if "Rust Converter Application" process has to be started then i need to interrupt him.

[hassan676]

Thankyou for your reply @omersiddiqui5482
I'm looking forward to your opinion and the experts you tagged

[mustansir44]

Good luck for the restoration. I am nearly done with my khyber restoration. If you need any help kindly, I will be happy to help.

Rust Converter: Converts Rust into chemical over which paint can be applied. Just thoroughly clean the surface apply rust converter let it sit for 12-24 hrs and then paint over it
Note that rust converter and rust remover are 2 totally different things. Rust Remover is an acid that corrodes rust and has to washed with baking soda or some basic chemical thoroughly sometime after application.

[hassan676]

Thankyou for your kind reply @mustansir44 bhai. I will surely need your expert opinion. I'll send you a message and we can connect over phone. One question is that does the rust converter need to be applied before "puteeen" and "astarrr" stuff are done? Means right after denting on the bare raw metal surface?

[hassan676]

Today i again visited the workshop. I am sharing the pictures of the cars after denting is completed. Today painter will start cleaning all the outer surface with "sandpaper". Do have a look at the pictures attached and please give your reviews/comments/suggestions. Thankyou

[nnabeel]

Oh god....this is too much rust. but its good u have replaced most parts.

just make sure that ur roof remains on it original shape and size and doesnt looks like doom shaped.
also measure the gaps between the doors and the sides.

[hassan676]

Thankyou for your reply. I tried my level best to ask denter to be extra careful about the roof but he was very irritated due to "desi roof" and was insisting k desi roof hai aur genuine wali baat nai aaye gi..So my reply was to do it to the best possible level.

Please elaborate a bit more by what gaps are your referring to between doors and sides?

[Moderator]

[hassan676]

Hey guys, Please take some time to have a look at this thread too I'll be really glad to get the suggestions and input from the expert PakWheels family. @speedster_101 @Deadly_Flame @Xulfiqar @omersiddiqui5482 @nnabeel @brownrose78 @margallar @capsat @nnabeel Please feel free to tag more people so we can get more of their suggestions and inputs here. Let's make this project a remarkable success
Looking forward to hear from the PakWheels community.

[brownrose78]

Immediately contact @mustansir44 as he has recently applied rust converter, so this is the right time to do that.

[hassan676]

Already contacted him and talked with him about that.

[brownrose78]

Your car has too much rust and it has high chance to reoccur within next 12 months after complete paint so do properly the rust handling step.

I have not personally done in my car but heard by various members about sand blasting techniques for tackling rust issue. If possible, check that option too before handing over to painter

[hassan676]

Thankyou @brownrose78. The denter has completely removed the rust. The rust you are seeing is due to the recent rain, it's surface rust. The painter is saying he will start scratching with "sand paper" tomorrow. I can talk to him about rust handling techniques but to be honest these people don't seem serious about this, so i need to force him or convince him for that tomorrow as he is about to start "Asterr".

I will also search about sand blasting if it can be done in Rawalpindi.

[brownrose78]

My denter showed Laziness in Rust handling, consequently I am suffering it after just 15 months so don't come in gossips of your Denter.

Anyways which color you opt for this project? Same white or different?

[hassan676]

Sorry for the rust showing up in your car. You are absolutely correct, we should not listen to the gossips of these Denters/Painters. I think i will tomorrow morning force him to scratch complete paint from diggy/bonut and everywhere else using "Sand papaer/raigmaal" and then i will buy some good rust converter and give him and ask him to apply under my supervision. I think it's a very wise decision to apply this at this stage rather than suffering after a year or so.

And yes i am going for the same white paint.

[Hassan1991]

which one did you used?

[nnabeel]

I am talking about the gaps as marked in the pics. check with some other khybers near by you so u will get the idea. these gaps will become more visible once paint is done and the door rubbers are installed.

as for the rust remover, do it right now as its the best time. the remaining paint can be removed by paint remover, Kharacha hoga but it will be better than doing it with the welding torch.

one thing u missed in the whole process is the area behind wiper motor. that area is the most no reachable area and gets rusted easily. treat it also.

Plus, u had a big crack in the frame on left side behind fender, i would suggest to make fender braces for both sides so it will make ur car structure sturdy. pics attached for reference.....ask ur dentar to take measurements and make at this moment as the car is bare.