Suzuki Khyber 1989 Restoration

[soulconquerer246]

since u are in the process of getting ur dashboard re-installed ,,, just a small advice ,, make sure its placed inch to inch perfect ,, minimal error will result as never ending plastic disturbance noise on every rough patch of ride... i have been victim to it in past and it really keeps disturbing you every day...

[mustansir44]

JazakAllah. Noted. Will keep an eye on it.

[mustansir44]

Wiring in Full Swing:

1. All Wiring in done with extreme measures. I-Joint Ferrules and heat shrink sleeve were used on every few joints in wiring.
2. New Japanese Tin coated lugs are installed with tin coated bolts.
3. Heat resistant pipe and sleeve are used.
4. New Connectors are used to mitigate joints in wiring and wiring can be close to genuine (Grip to Grip)
5. Original Zip Ties are being used.
6. New (aka Kabli) Dashboard and Interior Wiring was sourced from SherShah.
7. Every gauge and warning light in speedometer and dashboard is being made functional as per user manual.

Terious Kid Relay Box to be Installed:

Automatic Fan Connector:

Brake Oil Wire Connected:

[capsat]

while the car is at workshop please remove wiper mechanism scrub clean with wire brush remove rust paint it with Rustoleum black or clear double coat. it will be protected from rusting for another decade. change plastic bushes and use silicon grease to keep mechanism working well.

[mustansir44]

Yes Indeed. Already told the mechanic to dis-assemble and give them to us. Already bought plastic bushing and cover.

[nnabeel]

Nice work.

Paint the coil or clean it.
clean the oil resorvoir also.
paint the front show black, why paint has not been done properly.
shocker mounts need attention.

if you are doing such a detail and zero error wiring, why not pass all the wiring thru fenders and wiper area and make a clean engine bay like cars in cars shows where the wiring is least visible.

[mustansir44]

Yes. I am too thinking to paint the coil and clean oil reservoir. Paint will be applied once wiring has been sorted out.

I don't know what you mean by shocker mount needs attention. I think they are perfectly fine. Maybe masking tape is showing something wrong with the shockers.

[nnabeel]

OK, the masking tape made it look weird. no problem

[mustansir44]

New Update:

Car Denting + Painting + Electrical Work + Mechanical Work is Complete:

Some Trims still remaining to be installed:

Engine Bay + Wiring Done: (P.S. Engine Bay needs cleaning)

Went to Shershah in Search of Genuine Window because aftermarket were installed previously and also could not find better quality new Windows in market.

Our Cars Speedometer Circuit was blown and several circuit lines were bypassed in order to make it work. So, we sourced whole Kabli Speedometer Gauge from Shershah for 1000 Rs.:

[mustansir44]

Next on the list is to restore the Interior:

We are unable to source some of the Interior Trims like Speaker Trims, Trunk Base Trim, and few more

[nnabeel]

cool man!

the wiring works looking excelent and clean. Lets hope everything works well.
do use vapour barrier/ plastic sheets between the door cards and doors.
the seats looks like they are gone and need a full refurbish, sherhsha se koi acha set utha letey.

what else u found in shershah.

[brownrose78]

@mustansir44
Masha Allah, restoration process of your Swift/Khyber is progressing very very slow but very well

Point # 1: Brake Boo. seems quite dirty, get it serviced & cleaned; if color requires, then repaint it in black just like you did with ignition coil.

Point # 2: BHR (Bonnet holding Rod) has clip here which keeps it stagnant and provide friction during movement. Install that missing clip here.

Point # 3: Seems rusty part in picture; try to treat it too to restrict rust from spreading

Point # 4: Close-up picture required. How it has no space for A/C on/off switch button + bracket condition for installation of Din-1 stereo.
Nowadays quite interesting Chinese Single DIN Car Stereos are coming like: https://www.youtube.com/watch?v=E0fFI71QD9k

Roughly, standard is
Single DIN(Din-1 or 2x7") has Width: 7 inches, Height: 2 inches
Double DIN(Din-1 or 4x7") has Width: 7 inches, Height: 4 inches

Point # 5: Install Fuses cover, fill cutted holes, Fix position of Bonnet opening Lever

Point # 6: Make your external Fuse & relax Box diagram so that you can remember later on the path way; it will help quite in troubleshooting Later on.

Point # 7. Install Bonnet buffer here; it comes in Round shape with written PS usually new ones in golden color while black color rubber buffers are also available

Point #8: Install new holding clip for BHR (Bonnet Holding rod)

[ahmed_11]

Since you’re paying so much attention to detail, I’d like to highlight this.

The installed door handles are of rear doors; those too installed in wrong direction.
Please see below reference pictures.

Front ones:

Rear ones (installed in correct direction):

[nfsmostwanted]

You're from Karachi? from where you got the bodywork done?

[mehrozniazi1]

whats the update on the project ?

[mustansir44]

cool man!

the wiring works looking excelent and clean. Lets hope everything works well.
do use vapour barrier/ plastic sheets between the door cards and doors.
the seats looks like they are gone and need a full refurbish, sherhsha se koi acha set utha letey.

what else u found in shershah.

JazakAllah for the kind compliment. Yes will InShaaAllah install vapour sheets when interior will be done.
So, we contacted the person in shershah before going and he told us that he has speedometer for 8000. When we reached Shershah we decided to go to place beside Layari Express way where car are scrapped and found an old Khyber standing there. We sourced speedometer and Front Driver Side Window from there at very reasonable rate. They also had all spare parts of Khyber from Dashboard to Engine to most of the Interior trims.

@mustansir44
Masha Allah, restoration process of your Swift/Khyber is progressing very very slow but very well

Point # 1: Brake Boo. seems quite dirty, get it serviced & cleaned; if color requires, then repaint it in black just like you did with ignition coil.

Point # 2: BHR (Bonnet holding Rod) has clip here which keeps it stagnant and provide friction during movement. Install that missing clip here.

Point # 3: Seems rusty part in picture; try to treat it too to restrict rust from spreading

Point # 4: Close-up picture required. How it has no space for A/C on/off switch button + bracket condition for installation of Din-1 stereo.
Nowadays quite interesting Chinese Single DIN Car Stereos are coming like: https://www.youtube.com/watch?v=E0fFI71QD9k

Roughly, standard is
Single DIN(Din-1 or 2x7") has Width: 7 inches, Height: 2 inches
Double DIN(Din-1 or 4x7") has Width: 7 inches, Height: 4 inches

Point # 5: Install Fuses cover, fill cutted holes, Fix position of Bonnet opening Lever

Point # 6: Make your external Fuse & relax Box diagram so that you can remember later on the path way; it will help quite in troubleshooting Later on.

Point # 7. Install Bonnet buffer here; it comes in Round shape with written PS usually new ones in golden color while black color rubber buffers are also available

Point #8: Install new holding clip for BHR (Bonnet Holding rod)

Point 1: Yes Engine Room is in need of thorough Cleaning

Point 3: Alternator has a little surface rust.

Point 2, 5, 7, 8: I am trying to source the parts.

Point 4: Our AC guy has sourced the button and there is area in the AC control panel for the button. Will post close-up picture soon InShaaAllah

Stereo system will be installed later when Speaker Trims are sourced.

Since you’re paying so much attention to detail, I’d like to highlight this.

The installed door handles are of rear doors; those too installed in wrong direction.
Please see below reference pictures.

Front ones:

Rear ones (installed in correct direction):

@ahmed_11 They are temporary installed. We have sourced front Door Handles and they will installed when Interior work is done.

[mustansir44]

You're from Karachi? from where you got the bodywork done?

.Yes I am from Karachi. The body Work was done in Gulshan-e-Iqbal, Block 5, near Rab Medical Hospital Denter name is Arshad and Painter name is Arif.

whats the update on the project ?

The car is now with us. Denting, Painting, Electrical and Mechanical work is complete. Some minor correction is needed here and there. AC work will be done on Friday and Interior work by the end of this week InShaaAllah

[kunrian]

Please share detailed pics after completing all work.

[nnabeel]

Some small points:

Paint the bonnet rod.
If possible, take out the nuts which can be taken out like head cover bolts, air cleaner, shocks mount bolts etc etc. get them galvanized or get them sunn black. they will give a clean look.

pls take out the wiper washer nossles that are mounted with 2 screws on both sides. get them clean and buff too

The battery stand should go black painted also

Buy some warning stickers from magazine lane like
one for the radiator fan shroud
one for the battery
one for the AC gas

[mustansir44]

Please share detailed pics after completing all work.

Ofcourse InShaaAllah.

Some small points:

Paint the bonnet rod.
If possible, take out the nuts which can be taken out like head cover bolts, air cleaner, shocks mount bolts etc etc. get them galvanized or get them sunn black. they will give a clean look.

pls take out the wiper washer nossles that are mounted with 2 screws on both sides. get them clean and buff too

The battery stand should go black painted also

Buy some warning stickers from magazine lane like
one for the radiator fan shroud
one for the battery
one for the AC gas

Noted. Some of the Nuts and Bolts are Galvanized and majority of them Zinc Coated Japanese Nuts and Bolts. Head Bolt Nuts are Galvanized but are dirty and greasy in the picture. Will share picture after deep cleaning.

The Wiper Nozzle was washed and one them was chocked so it was cleared also. Yesterday I installed new Wipers and adjusted the nozzle to spray properly.

I will try my best to paint battery stand to black and will try to buy stickers from Magazine Lane InShaaAllah