Suzuki Khyber 1989 Restoration

mustansir44 (Mustansir Billah) 2020-11-17 01:33:24 +0500 #1

Greetings brothers and sister. My family has owned khyber since 2011 and bought it from first owner. It is since been a "daily driver" for our family. We were unable to drive it on regular basis for the past year or two because of its routinely wiring failure and rust accumulation in body panels. Moreover, it was consuming some engine oil so, engine rebuild was also due.
We finally decided to restore it. Our project khyber has now started...

mustansir44 (Mustansir Billah) 2020-11-17 01:39:38 +0500 #2

Here are some pictures

alibintahir (Ali bin Tahir) 2020-11-17 02:06:22 +0500 #3

Good Luck to you brother.

saad2006 2020-11-17 12:54:55 +0500 #4

Good Luck

Hassan1991 (Electrical Engineer ) 2020-11-17 13:23:31 +0500 #5

Ask your denter to cut rusted pieces and then weld new ones. Don't let him weld upon old rust pieces.
Best of luck

mustansir44 (Mustansir Billah) 2020-11-17 14:57:18 +0500 #6

JazakAllah all for your kind wishes.
@Hassan1991 Thank you for the concern. Me and My brother had an extensive discussion with the denter before starting the project about the same issue.

Below is a before image of rusted door

After image:

Comparison of both:

mustansir44 (Mustansir Billah) 2020-11-17 15:04:54 +0500 #7

Another visit to the denter:
Found some new rusted spots beneath the paint. The denter suggested to replace as much of the panel to avoid spread of rust.

The marked piece will replaced.

Most of the rear quarter panel will be replaced and patched

The whole floor board will be replaced:

This fender will be replaced by taiwan assembled counterpart:

Another door under surgery:

mustansir44 (Mustansir Billah) 2020-11-18 01:04:08 +0500 #8

I require help regarding engine overhaul. Engine is consuming some oil (not a lot) and I think it needs new piston rings. The engine blocks needs welding and resurfacing as water jackets are rusted. Any good mechanic in Karachi which can restore engine to factory specs?
@omersiddiqui5482
@speedster_101
Below are few images:

speedster_101 2020-11-18 01:08:37 +0500 #9

I am from Islamabad. Can't refer you to a good mechanic in Karachi.
@capsat can help

brownrose78 (brownrose78) 2020-11-18 02:11:04 +0500 #10

In Karachi, Mechanic Rafique aka Ustaad Rafiq is very expert in overhauling old engines specially Khyber

His contact # is 0331-2022756
Location is in neighbourhood of Japan Autos near Iqra City, Abul Hasan Ispahani Road.

2nd is Mohsin Automobiles at Ghareebabad is gaining popularity over mechanical work specifically swaps.

BTW from where, you are doing restoration works and any plan to restore dashboard.

mustansir44 (Mustansir Billah) 2020-11-18 02:16:08 +0500 #11

Thank you very much @brownrose78 will contact Rafiq InShaAllah. Body work is being done in block 5, Gulshan-e-Iqbal.
Yes! Dashboard needs repairing as well but once its dismantled, will get to know the condition more clearly.

brownrose78 (brownrose78) 2020-11-18 02:23:55 +0500 #12

From where in Gulshan block 5?

I am in Karachi and available 24/7 for any help/suggestion.

BTW are you interested in engine swap or your mind is of restoring it back to factory spec.

omersiddiqui5482 (omersiddiqui5482) 2020-11-18 09:31:21 +0500 #13

Are you observing the distortion in the valve seals.. have the engine properly checked.. and if there is excess warpage you will have to replace the block... Try the guys mentioned by @brownrose78 Bhai.. else check with Kamran (kami) opposite Lucky One he might help.. I maintainy Khyber with him...

mustansir44 (Mustansir Billah) 2020-11-18 11:01:49 +0500 #14

Just behind Childrens Hospital near Madni Mosque. I want to restore it to factory spec. In my mind, there is not much problem with the engine but will get to know when it is inspected by some professional. Moreover, we were unable to properly start and test the engine because of wiring failure.

mustansir44 (Mustansir Billah) 2020-11-18 11:06:46 +0500 #15

Thank you for your suggestion. Will have to check about valve seals. The engine is not opened until now. The pictures are from 1 year back when head gasket was changed.

brownrose78 (brownrose78) 2020-11-18 11:54:19 +0500 #16

I also have 1 Khyber in our home and few months ago, I had a plan to swap Vvti engine with Automatic Transmission and even went to swapping workshop and inspected my Khyber by them too but due to Brotherly suggestion by @omersiddiqui5482 I changed my plan and it is still perfect decision to stick with factory spec.

Mechanic Rafique is very experienced person, nowadays he is working on Cuore and happily surprised to see the level of perfection by him just yesterday.

For electric work, I also rely on electrician suggested by @omersiddiqui5482 to me, that's Auto Electrician Maani at near Sagheer Centre opposite to Luckyone. He is brother of mechanic Kami came under discussion above.

mustansir44 (Mustansir Billah) 2020-11-18 12:56:27 +0500 #17

yes the hassle to swap is too much. meter guage, wiring, radiator upgrade, etc. Our plan is also to stick with factory spec as much as possible. Any reference I can use for Rafique mechanic?

brownrose78 (brownrose78) 2020-11-18 13:50:28 +0500 #18

Yes you can give my references, recently he replaced Petrol tank pipe of my Khyber.

I have also talked to him just now to see wether he is free or now. He can take work now.

Other thing is pay your painter the rent of oven booth to get oven baked paint.

Also buy only good brand paint. There is paint shop Behined Children hospital in neighbor of Suspension shop

mustansir44 (Mustansir Billah) 2020-11-18 14:46:35 +0500 #19

Never got your name? hehehe...
Let me call him. I will go there and talk to him first. Not sure how the things will go from there. Would I have to take out engine and dispatch to his shop or should I take whole car there ( which might not be possible because denting work is in progress)?

Yes. before starting the restoration we agreed on oven baked paint. Also, can you specify any good paint brand?

brownrose78 (brownrose78) 2020-11-18 15:00:43 +0500 #20

Simply now, send your engine after dismantling to his shop.

In the meantime, your denting painting will be in process. After completing paint, bring your car there to install Engine, then wiring. You can send dashboard and seats to concerned persons.

Most of the things will go in parallel.