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Old 8th May 2010, 21:13   #1
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Default Diy-restoring Old Jalwa Horns

After thinking a lot i finally decided to get the good old jalwa horns in working order. Got them checked and repaired. The sound was just amazing and so loud that i decided to fit only one unit in my car.
Then came the phase to get them painted in order to make them look better. Asked Mr. P Kadam about the handling and the correct procedure to follow while working on aluminum surface and he was kind enough to provide the step by step procedure for preparation and painting. Strictly followed his words and finished the work on the lower half portion of horn assembly. Attached are some pics for reference.
In order from 1st to last:
1,2&3. Scrapping off old paint
4 & 5. Petrol washed the surface inside and out
6. Cleaning the remnants of paint.
7. First layer of coating. Berger Red oxide primer used.
8,9&10. Cleaning and repairing the cone gasket.
11,12,&13. Final outcome after 4 thin layers of acrylic paint.(work also includes the rubbing and painting process)
14. Horn Mechanism fitted back.
16. The material used.
17. Shot taken for comparing the physical condition.
18&19.General shots.

The other set will also be done up using the same process followed by the painting of horn caps in post office red. Waiting for the desired red shade to arrive in a week.
Attached Thumbnails
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Old 8th May 2010, 21:47   #2
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Quote:
Originally Posted by samsag12 View Post
After thinking a lot i finally decided to get the good old jalwa horns in working order. Got them checked and repaired. The sound was just amazing and so loud that i decided to fit only one unit in my car.
Then came the phase to get them painted in order to make them look better. Asked Mr. P Kadam about the handling and the correct procedure to follow while working on aluminum surface and he was kind enough to provide the step by step procedure for preparation and painting. Strictly followed his words and finished the work on the lower half portion of horn assembly. Attached are some pics for reference.
In order from 1st to last:
1,2&3. Scrapping off old paint
4 & 5. Petrol washed the surface inside and out
6. Cleaning the remnants of paint.
7. First layer of coating. Berger Red oxide primer used.
8,9&10. Cleaning and repairing the cone gasket.
11,12,&13. Final outcome after 4 thin layers of acrylic paint.(work also includes the rubbing and painting process)
14. Horn Mechanism fitted back.
16. The material used.
17. Shot taken for comparing the physical condition.
18&19.General shots.

The other set will also be done up using the same process followed by the painting of horn caps in post office red. Waiting for the desired red shade to arrive in a week.
Great Work. But why did you removed that paper sealing ???
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Old 8th May 2010, 21:52   #3
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Wow! Good one Sagarji. I have collected two good Jalwa horns till now. I suggest you too to pick up one or two more sets of these horns. The main issue with these horns are the point sets which are hard to find.
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Old 8th May 2010, 22:10   #4
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Great Work. But why did you removed that paper sealing ???
Initially was planning to mask the upper surface but when i tried to do so the paper sealing got me in trouble. Some portion of it came off sticking with masking tape so removed the entire gasket to protect it from being ruined.
@ Arun1100: Thanks for the appreciation. I know you have quite a few of them. When i purchased this set, it was still on the Amby which was to be scrapped so took it out. But here these guys (scrappers) sell it as scrap aluminum right away so its a bit difficult to get a pair. BTW have been trying to get one more set along with the long hooter one.(mainly seen on Selects and super selects) Yes you are right about the point sets. They are very hard to find.
Congrats on the latest acquisition of these horns which you got at a throw away price recently.
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Old 8th May 2010, 22:48   #5
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Quote:
Originally Posted by samsag12 View Post
Initially was planning to mask the upper surface but when i tried to do so the paper sealing got me in trouble. Some portion of it came off sticking with masking tape so removed the entire gasket to protect it from being ruined.
But now you will have to keep these horns away from Water. As you have now removed that sealing the electric coil could get wet and blow out. If possible insert the paper sealing again.
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Old 8th May 2010, 23:15   #6
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Drains the batt like crazy....!
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Old 8th May 2010, 23:46   #7
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Great job Sagar.. Jalwas are always special !
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Old 9th May 2010, 11:30   #8
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Originally Posted by iamback View Post
But now you will have to keep these horns away from Water. As you have now removed that sealing the electric coil could get wet and blow out. If possible insert the paper sealing again.
Oh i think you got me wrong. What i meant by saying this is that i removed the gasket when i masked the inner surface. After completion have put it back again. You can have a look at it in the pic no.14.

@Superselect Thanks for the complement.
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Old 10th May 2010, 20:02   #9
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A picture of the horn before it was worked upon. Can anybody state whether the bracket for mounting it to the car is a default one or have been fabricated.
Edit: It was taken off from a scrapped Mk2 Amby
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Old 10th May 2010, 21:19   #10
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Brings back memories of my father's Ambassadors !! Those things were the only one's that made cows move from the road !! LOL LOL

Nice restoration.
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