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Old 13th February 2012, 22:16   #1
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Default 1993 MM540 4X4 Restoration

Hey everyone,
Let me start by introducing myself, i'm Sachin Patrick from Bangalore, doing my architecture here, been an automobile enthusiast pretty much all my life.
It was a couple of years ago that i got bitten by the Jeep bug, after i took my brother and fellow bhp-ian, J_4_Jeep's CLASSIC out for a spin!
With a lot of hunting, i was able to acquire myself a 1993 MM540 4wd here in Bangalore. It was used in a convent all along, hence hasn't been exposed to any form of off-roading as yet.. Engine work done recently, 4wd disconnected, body has a bit of rust in certain places, overall condition: good.
The drive was excellent and not as i had been warned about its handling in city traffic as i had to travel about 60km a day, hence have decided to stick with the stock tyres for a while. A quick service, including oil change, radiator welding, stars changed, electricals set right and she was ready to use without any trouble whatsoever! In the next 6 months, i got the battery changed, Amaron FR750RMF, got the brakes overhauled, clutch overhauled, hood and cabin heat insulated etc.

After using her for almost a year now, i've decided to restore my jeep, in Wayanad at Erumad auto industries near Bathery, pictures will follow in a day or two.
I have budgeted the restoration under a lakh as of now, and decided to get the entire body scraped down, tinkered and repainted, door alignments checked, reconditioning of rims, removing indicators on fenders, half tailgate, roll cage, replace the windshield with an operable ventilated one, new seats, replace with nuts and bolts all the places that have been welded tight such as windshield hinges and soft top frame, new soft top, get the 4wd functioning etc.. Basically bring it back to stock, as much as possible.

As the workshop is in Wayanad, i'm able to visit it only on weekends, when possible and apologize for the lack in continuation of pics,
Let the pictures speak for itself
Pics of the jeep at the time of purchase

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At last, i left my jeep at the workshop the day after Christmas, and they started working on it soon enough. The tub had to be dismounted off the chassis for tinkering work, as rust had been showing in corners through the paint. Also as i will be keeping the jeep for a long term, i had asked for all the paste and filler to be scraped out. Initially i was hoping to have the body lead coated but was told they do not do that anymore.

Estimate given by the workshop:
tinkering : 7500 (including material)
painting: 8000
mechanical: 6000

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On my second visit, the tub had been mounted back onto the chassis, and the chassis painted olive green. This time i carried the windshield frame i found from the gujri at Shivajinagar after a lot of hunting, paid Rs.1500 for it including the glass, but later got the glass changed at City Glass in Mysore and got the frame buffed too.
Was able to find more parts in Safe automobiles in Mysore than any of the shops on JC road here in Bangalore.

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Got the tailgate from the Stanley dealer's thar that was being done up in a workshop nearby.
Finally the scraping work started and a coat of primer was put just before i had to return to Bangalore.

1993 MM540 4X4 Restoration-280120121018.jpg

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For the colour scheme, i had an option of beige/brown and green of off white and green, but decided to stick with off white and green, a scheme i borrowed from Mr.Roy's 540 that Ranjith did up. Hope you guys don't mind

1993 MM540 4X4 Restoration-12012012990.jpg
was an option in matte.

the tail lights and blackout lights were painted olive green.
Attached Thumbnails
1993 MM540 4X4 Restoration-270120121007.jpg  


Last edited by GTO : 16th February 2012 at 13:40. Reason: Merging both your posts.
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Old 13th February 2012, 23:27   #2
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Default Re: 1993 MM540 4X4 Restoration

Your 540 has clean lines and looks very well maintained. Congratulations. Some good rubber will do wonders on him. Please scratch off that black shading on your headlamps
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Old 14th February 2012, 12:27   #3
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Default Re: 1993 MM540 4X4 Restoration

Hi Patrick,

Please put in side windows at the rear. Having a fully closed body like that will be risky in metros where we have to keep switching lanes. You will not be able to see properly when you switch lanes.
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Old 14th February 2012, 16:57   #4
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Default Re: 1993 MM540 4X4 Restoration

Quote:
Originally Posted by 4x4addict View Post
Hi Patrick,

Please put in side windows at the rear. Having a fully closed body like that will be risky in metros where we have to keep switching lanes. You will not be able to see properly when you switch lanes.
Thanks 4x4addict,
new soft top work is in progress, and will be done within a week, have already experienced the difficulty with this in Bangalore traffic!

Quote:
Originally Posted by Ashley Nair View Post
Your 540 has clean lines and looks very well maintained. Congratulations. Some good rubber will do wonders on him. Please scratch off that black shading on your headlamps
Hey Ashley,
Thanks and yes i scratched off the black shading the day i got it itself and tyres aren't budgeted for as of now

Last edited by GTO : 16th February 2012 at 13:40. Reason: Removing our conversation as the thread is being moved back to public
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Old 16th February 2012, 13:42   #5
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Default Re: 1993 MM540 4X4 Restoration

Thread moved from the Assembly Line to the 4x4 section. Thanks for sharing!
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Old 21st February 2012, 16:52   #6
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Default Re: 1993 MM540 4X4 Restoration

On my next visit a week later, i was hoping to see some progress and i did! the base coat had been on and the interiors were painted in silver hammertone paint.

Paint material cost:
Paint set 1.5L asian paint ppg bilux, Rs.3600 (1750 per liter)
Body filler, thinner, metal paste. etc Rs.4500

Interiors: hammertone silver
Body: Diamond white
Rims: dark green
Hubs: red
Chassis: olive green

After a thorough check up, the body was wave free, and had pretty good lines, doors and hood well aligned. Took a while to reach here with the tinker taking things slow but was worth the wait!

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The next morning, the final coat was done, it did show a few spot weld dents but hardly noticeable. Was a little apprehensive about the painter but he pulled off a good job!

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Had to drive back to Bangalore right away, and planned to return within a week to drive the jeep back home. The following week, the fittings were to be done, with electricals and also get the 4wd functioning and finally the upholstery work.

One axle and the propellor shaft were missing, but was able to find it in Mysore, at the gugri for 1750.
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Old 21st February 2012, 18:22   #7
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Default Re: 1993 MM540 4X4 Restoration

So far the tinkering and Paint job seems good. I'd love to see the color scheme when its finished. I hope you will be getting new shoes for her, have you decided which ones?

Keep the pics coming.
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Old 22nd February 2012, 22:32   #8
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Default Re: 1993 MM540 4X4 Restoration

Patrick, How did you chose this garage? Are you from around Erumad?

This garage used to be the M&M authorized service branch of CAI (Coimbatore Auto Industries) until sometime ago. They do a good job.
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Old 22nd February 2012, 23:46   #9
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Default Re: 1993 MM540 4X4 Restoration

Hey Jeeva,
Heard about this place when i went to visit my grandmom in Cherambadi, so took the jeep there and got a service done, they did a really good job.. This was in June. Drove down there this christmas and decided to leave it there. The guys there were really helpful, and called everyday regarding the progress. I would surely recommend this place!
And yes, they still are a M&M authorized service centre, not sure about the CAI
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Old 3rd March 2012, 19:07   #10
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Default Re: 1993 MM540 4X4 Restoration

Hey Sachu ,

What a small world we live in Firoz is my Distrubutor partner in Dubai , and he has been closely keep tab of your Jeep and the project


Sarin Doie
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Old 7th March 2012, 20:43   #11
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Default Re: 1993 MM540 4X4 Restoration

Assembly day 3, after painting was completed.
rub rails
new tail lights
jerry can mounting
new reverse light
new rear search light
tow hook
headlight grills
new windshield
new wiring kit
new switchboard

1993 MM540 4X4 Restoration-dsc01328.jpg

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measurements taken at the upholstery shop

1993 MM540 4X4 Restoration-dsc01335.jpg

day 4: water wash and polishing
day 5: upholstery work - new seat covers and soft top
drive to bangalore

pics coming up soon!
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Old 10th March 2012, 00:00   #12
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Default Re: 1993 MM540 4X4 Restoration

1993 MM540 4X4 Restoration-dsc01333.jpg

design intended for seat covers
1993 MM540 4X4 Restoration-270120121009.jpg

buttons for soft top, picked them up from a shop on jc road, the guy there seems to do a pretty good job, picked up the YKK zippers, and black canvas from there as well. @200 a metre.
1993 MM540 4X4 Restoration-310120121040.jpg

Having some trouble with the starter motor, fails to crank at times, does start easily with a push tho, armature worn out apparently, would it be advisable to work on the existing one (already worked on once, changing of bushes), or get a replacement from the gugri, hes offered me 1.7k for what i have, or if a brand new one, for the peugeot 2.1, what are my options apart from tvs.
Also fuel pump has to be worked on, feels like theres a slight loss of power and top end acceleration. Was suggested to go to Saravana Diesels in bangalore, but are there any options to that too? would like to check the compression as well.
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Old 15th March 2012, 09:33   #13
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Default Re: 1993 MM540 4X4 Restoration

Done with water wash and polishing and ready for upholstery work finally

1993 MM540 4X4 Restoration-190220121086.jpg
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1993 MM540 4X4 Restoration-dsc_0513v.jpg
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Old 24th March 2012, 09:27   #14
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Default Re: 1993 MM540 4X4 Restoration

Shes done!! Work with the upholstery got done at 8 in the evening, and we headed to Bangalore straight from there.. Clicked a few pics on the following day..

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now the painter messed up with the colour of the shocks, i had asked him to paint it black of factory blue, but unfortunately, this was his idea of blue, will change it soon to black or red, suggestions welcome
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Old 26th March 2012, 10:07   #15
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Default Re: 1993 MM540 4X4 Restoration

Patrick,

That's one wonderfully restored beauty I must say !

She has been tastefully re-done. The shock absorbers can be painted black. I guess that will go well with the olive green under belly.

I would suggest you get the following add ons on the 540.
1. Insect mesh for radiator grill.
2. new set of all terrain tyres. BF Goodrich should be a killer on looks.
3. Match the tyres with a good set of alloys.

Congrats once again for your lovely toy.
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