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Old 15th March 2011, 17:53   #1
GTO
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Default Mahindra Classic 2.5L : In Tight New Clothes!

Link to my 2.5 L diesel engine swap thread (Mahindra Classic 4x4. 2.5 Liter Diesel. Back on the road!)

It had been over 7 years since I last got the Jeep painted (in '03). For an old school Jeep that's been exposed to the elements, the paint job held up rather well. Rust - enemy no.1 - of all Mahindras was most prominent around the bonnet area....but was in acceptable condition otherwise. I could have gotten away with a patch up job. However, we decided to go the whole hog especially since, and again, it was 7 years since the last full repaint. This Jeep, after all, is a partner for life.

Ferdi from Milestone really built it like his own Jeep. I visited Milestone all of 3 times in the 4 weeks that it took to complete the job. Yet, everytime I swung by, Ferdi had made some fab, independent decisions (matt black paint on the gear console, for example) and gone ahead with the implementation. He knows he doesn't need to ask me.

Thanks also to Senior Mod Jaggu for his tips on making the Jeep rust proof (Wurth et al).

In terms of mechanical work, there wasn't much. The new engine & ancillaries were perfectly installed. The only two mechanical requirements were a busted steering rack (gone bad due to excessive knocks by rocks!) and that the front left brake was grabbing (after offroading through deep muck in Jan). That's it...this despite the Jeep not having visited the Garage in a long time.

Of course, as a precautionary measure, I got all the lubes (engine, diff etc.) changed.

Results:

Mahindra Classic 2.5L : In Tight New Clothes!-1.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-2.jpg

Slick looking hinges (different from OEM). The Classic hinges - due to their nonsensical design - are a rust magnet. Also notice the stainless steel bolts. We have used them everywhere as they don't rust:
Mahindra Classic 2.5L : In Tight New Clothes!-3.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-4.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-5.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-5b.jpg

Clear lamp indicators:
Mahindra Classic 2.5L : In Tight New Clothes!-6.jpg

Heavily coated underbody is obvious:
Mahindra Classic 2.5L : In Tight New Clothes!-7.jpg

7 year old SS bars have held up well:
Mahindra Classic 2.5L : In Tight New Clothes!-8.jpg

Thar-style rough finish canopy:
Mahindra Classic 2.5L : In Tight New Clothes!-9.jpg

Old seats have also held up well:
Mahindra Classic 2.5L : In Tight New Clothes!-10.jpg

Got rid of the rust-bucket drawer under the driver seat. Also notice the style of the mats. These are awesome for 4wheeling:
Mahindra Classic 2.5L : In Tight New Clothes!-11.jpg

Clean interiors. Ferdi moved the drivers seat a further inch back. No longer too cramped, driver legroom is like most hatchbacks:
Mahindra Classic 2.5L : In Tight New Clothes!-12.jpg

Got rid of the rear seat. No one used it anyways, looks better now and can carry 4 XL size airport bags:
Mahindra Classic 2.5L : In Tight New Clothes!-13.jpg

Part sourcing problem for discontinued cars? What you talking about? Ferdi gets me all the parts I want for my Classic, and then some. New tail-gate locking mechanism:
Mahindra Classic 2.5L : In Tight New Clothes!-14.jpg

Looks crude, I know. But if the Classic wing mirrors get stuck in a tree (for example, while offroading), they crack the windscreen frame. Local reinforcement
Mahindra Classic 2.5L : In Tight New Clothes!-15.jpg

Picture credit : Moderator Stratos

Last edited by GTO : 16th March 2011 at 08:53.
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Old 15th March 2011, 18:04   #2
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Default Re: Mahindra Classic 2.5 : From Rust -> New in <1 Month

Work-in-Progress pictures

Week 1:

Mahindra Classic 2.5L : In Tight New Clothes!-1.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-2.jpg

Three mechanics working on my Jeep, at the same time:
Mahindra Classic 2.5L : In Tight New Clothes!-3.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-4.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-5.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-6.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-7.jpg

5 days later:

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6 days more:

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And a week later:
Mahindra Classic 2.5L : In Tight New Clothes!-b.jpg

Mahindra Classic 2.5L : In Tight New Clothes!-b-1.jpg

Last edited by GTO : 15th March 2011 at 18:14.
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Old 15th March 2011, 18:18   #3
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

Hi Rushabh,

The Looks superb, I suggest you fit, the Insect Mesh Frame with a brushed Aluminium inner mesh.

Regards,

Arka

Last edited by ex670c : 15th March 2011 at 18:20.
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Old 15th March 2011, 18:21   #4
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

I am already fan of your classic GTO.
and this is treat now, very well paint job, looks all new now.

Thanks,
Vishal.
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Old 15th March 2011, 18:39   #5
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

Awesome pics GTO sir. You got an awesome ride. I just love the 4th pic. Claps claps.
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Old 15th March 2011, 18:41   #6
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

A hot rod, ain't it rush? Well executed paint job and brilliant finishing! How about inviting me for an official test drive?

Last edited by sidindica : 15th March 2011 at 18:43.
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Old 15th March 2011, 18:44   #7
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

Thats a smart soft top. I have ordered the original one from Bombay too and should receive it this week.

Where did you get the soft top? How much?
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Old 15th March 2011, 18:46   #8
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

I've just got one thing to say....on second thought, since those words won't get past the censor board even if they're in a coma, here's the next best thing: 'Hubba hubba!'

Seriously that is one fine looking Classic. Das ist eine schöne Jeep!
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Old 15th March 2011, 18:49   #9
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

GTO ,

What a beautiful Jeep.The new paint job brought the Jeep back in to the glory.Can you post the pics of the soft top ? I think the softop need little more attention in detailing.
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Old 15th March 2011, 19:06   #10
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

GTO, Congrats and My best wishes for the new avatar of your classic!!!. It is very beautiful in all ways. I feel very jealousy
If God showers his grace,I would also like own such a mean machine one day
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Old 15th March 2011, 19:20   #11
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

Wow, fantastic finish. Also gives that new car feeling.

Didn't realize you had a single lever 4WD stick.

BTW, why is the Jeep still sporting ancient Michelin LTX tyres?
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Old 15th March 2011, 19:55   #12
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

Quote:
Originally Posted by GTO View Post
Slick looking MM540 hinges. The Classic hinges - due to their nonsensical design - are a rust magnet:
GTO, what an awesome looking Jeep, congrats on a job well done. Which radiator fan are you using?

IIRC, the bonnet hinge shown in pic is not from a 540, must be from some other model, 540 hinge looks like this:-

Mahindra Classic 2.5L : In Tight New Clothes!-15072009052.jpg

Spike
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Old 15th March 2011, 20:04   #13
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

Fantastic job. The pics of the Jeep are awesome as well.

Can you finally change your profile pic to the 1st or 5th one please :-)
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Old 15th March 2011, 20:19   #14
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

Dear Rushabh - it is indeed good to see your CL340 classic attended to once again. I would have preferred a complete rebuild from scratch after removing the engine / transmission / axles out of the chassis. That way during paint, you can progress as if the car is getting built on the assembly line. This will take you through another 5 years, so it is good. Please replace the tyres if required. I saw it in November 2008. I would want to drive it one of these days.

Best regards,

Behram Dhabhar
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Old 15th March 2011, 20:40   #15
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Default Re: Mahindra Classic 2.5L : In Tight New Clothes!

Way to go GTO. Ferdi has done a super job as usual....
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