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Old 1st July 2020, 19:12   #1
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Default DIY: Converting a Maruti Zen into a sleeping bed!

Hello! I hope everyone is doing good in these unprecedented times.

This is going to be my first long-ish post on Team-Bhp. Please excuse me for any errors.

Firstly, I am prepared to receive a lot of condemnation from bellow bhp-ians for rendering a loved by everyone and perfectly running good ol zen no more road-worthy. Let me tell you, I had reasons which you shall understand as you read on. If not this, it would be scraped.

Our company was working on a project in a remote place in Haryana and we acquired an old 1998 zen to ferry manpower and sometimes tools & tackles to and from the project site to the nearby market (everything within a 5km radius). For just about 40k we had a nearly 57000 kms done in quite a good condition.

The project was completed in the mid of 2019 and the Zen was brought to our office in New Delhi.
The lil boy returned almost 13-14 km/ltr in the last highway journey it would ever undertake which I feel is pretty decent for a 20 year old carb engine.

I used to drive the zen around my house but soon realised that repairs to the brakes & steering were needed if I wanted to continue driving the little bean around anymore.

As the car was nearly 2 decades old, it could not be driven in Delhi-NCR legally (NGT rules), neither could it be sold owing to the some complications which made it nearly impossible for the new owner to register the car in their name. I was in no way selling a car with it still being registered in our company’s name.

The bean sat in a corner for a few months. We decided that the only way forward was to scrap it. It was then that my younger brother asked me if he could plonk out the engine and convert it into a generator for his engineering college project. I was thrilled by the idea. The entire process of dismantling the engine and converting it into a generator would give him a ton of practical experience about engines and familiarity with using tools. I instantly agreed.

We drove the Zen to our factory and started the dismantling procedure. The entire project was executed by him and I offered only some guidance when required. He was able to successfully take out the engine along with transmission, fuel tank etc. and fabricate a mounting trolley for them. He even started the engine on the trolley. We were in the talks of buying a suitable alternator when the pandemic hit us and it was no-go for my brother to scavenge for an alternator in the densely populated areas in Delhi. The entire plan for the generator was pushed aside.

Now, whenever I went to our factory, I saw this engineless beany boy staring at me like asking me to save it from the gallows.

While working one day, I was suddenly struck by one of my old childhood memories and I totally knew what I wanted to do with the engineless zen. It was to made into a bed! I called up my brother and told him what I was planning to do. Being a grease monkey that he is, he got all excited to be finally able to get his hands dirty again.

The design was planned in such a way that:

The bed should be totally flat and comfortably usable by a 6 foot adult.
All four doors should remain operable using the existing door handles and opening them would reveal the storage space.
The boot should have flap-type lid, which would offer access to even more storage space.
The Bonet would also open and offer more storage space.
The headlights and tail-lights should be fitted with small LED’s - which would act as night lights.
A bluetooth speaker system should be installed in the engine compartment.
The car should remain as original as possible except the roof.

We have nearly completed this project and have complied a video of the process. I would love to have your inputs on making it better.



As I am not so good with words, I would let the pictures do the talking. The car bed is complete and for the generator, I need help from fellow bhp-ians regarding the selection and correct coupling of the alternator shaft to the engine shaft. As of now the engine along with the fuel tank, cooling system etc has been mounted on to a movable trolley (which shall be the chassis of the generator as well) using the existing engine mounts, transmission has been removed and the engine is in working condition.

THE PROJECT CAR
Exterior
DIY: Converting a Maruti Zen into a sleeping bed!-1.jpeg
Interior
DIY: Converting a Maruti Zen into a sleeping bed!-2.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-3.jpeg

Parked Inside our factory - My brother drove it here
DIY: Converting a Maruti Zen into a sleeping bed!-4.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-5.jpeg

The stripping begins:

Bumpers, headlights and grill taken off
DIY: Converting a Maruti Zen into a sleeping bed!-6.jpeg

The interior is stripped, seats, dashboard etc.
DIY: Converting a Maruti Zen into a sleeping bed!-7.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-8.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-9.jpeg

Fenders are removed to avoid any damage to them during the removal of the engine and other accessories
DIY: Converting a Maruti Zen into a sleeping bed!-10.jpeg

Cleared engine bay of unwanted parts such as compressor, wiper motors etc. to make more space for engine removal. Engine mounts can now be accessed easily.
DIY: Converting a Maruti Zen into a sleeping bed!-11.jpeg

The zen then placed on in-house fabricated jacks to raise its height enabling easier access to the silencer and fuel tank disassembly.
DIY: Converting a Maruti Zen into a sleeping bed!-12.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-13.jpeg

The axle is removed as they are connected to the transmission. We took out the engine along with the transmission.
DIY: Converting a Maruti Zen into a sleeping bed!-14.jpeg

A pulley is mounted on an in-house fabricated hoist and using chains, the engine is lifted off the zen after unbolting all the engine mounts.
DIY: Converting a Maruti Zen into a sleeping bed!-15.jpg

A time-Lapse video of the engine removal process.


The engine placed on a trolley. The engine was removed while still coupled to the transmission.
DIY: Converting a Maruti Zen into a sleeping bed!-17.jpeg

Fuel Tank Removal
DIY: Converting a Maruti Zen into a sleeping bed!-18.jpeg

The silencer was also removed. Don't have pictures. The Zen back on its feet.
DIY: Converting a Maruti Zen into a sleeping bed!-19.jpeg

Once the engine was removed, saw some crazy corrosion damage to the chassis. Regretted driving it instantly. The majority damage was on the battery side.
DIY: Converting a Maruti Zen into a sleeping bed!-20.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-21.jpeg

The repair work to the chassis begins. Cut out the corroded metal, welded fresh new metal in its space and applied red-oxide.
DIY: Converting a Maruti Zen into a sleeping bed!-22.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-23.jpeg

Bruised up boy
DIY: Converting a Maruti Zen into a sleeping bed!-24.jpeg

Repainting using spray paint cans.
DIY: Converting a Maruti Zen into a sleeping bed!-25.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-26.jpeg

The windshield was removed and the roof was cut off. A time lapse video of the process:

DIY: Converting a Maruti Zen into a sleeping bed!-28.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-29.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-30.jpeg

The re-fitment starts, the door frames and small stubs of the frame were intentionally left out for a later stage.
Bonnet installed
DIY: Converting a Maruti Zen into a sleeping bed!-31.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-32.jpeg

.....Continued in the next post

Last edited by RS90 : 8th July 2020 at 19:59. Reason: Adding more details
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Old 8th July 2020, 19:37   #2
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Default re: DIY: Converting a Maruti Zen into a sleeping bed!

....continued

Headlights installed. One is broken, will replace soon.
DIY: Converting a Maruti Zen into a sleeping bed!-32.jpeg


Bumpers reinstalled
DIY: Converting a Maruti Zen into a sleeping bed!-33.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-34.jpeg

Notice how the front end has risen post the removal of engine weight.
DIY: Converting a Maruti Zen into a sleeping bed!-35.jpeg

The bed frame fabrication begins:
DIY: Converting a Maruti Zen into a sleeping bed!-36.jpeg

The frame majorly complete
DIY: Converting a Maruti Zen into a sleeping bed!-37.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-38.jpeg


The boot was welded shut to the body
DIY: Converting a Maruti Zen into a sleeping bed!-39.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-40.jpeg

Additional members were added to the bed frame to make it more sturdy and red-oxide was applied to prevent rusting.
DIY: Converting a Maruti Zen into a sleeping bed!-41.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-42.jpeg

Ply Wood was procured and was cut to match the contours of the car before being screwed to the new frame.
DIY: Converting a Maruti Zen into a sleeping bed!-43.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-44.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-45.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-46.jpeg

The plywood mounted on the frame.
DIY: Converting a Maruti Zen into a sleeping bed!-47.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-48.jpeg

There were a lot of sharp and rough edges which were potentially very dangerous. Those protrusions and edges were sanded off and PVC pipes were used to provide a clean look.
DIY: Converting a Maruti Zen into a sleeping bed!-49.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-50.jpeg

PVC pipe installed on th sides, a full sized mattress is placed on the bed.
DIY: Converting a Maruti Zen into a sleeping bed!-51.jpeg

Flexible PVC pipe was installed to cover the remaining part
DIY: Converting a Maruti Zen into a sleeping bed!-52.jpeg

As the boot was welded onto the car, this flip type lid was made using hinges to access the boot store area.
DIY: Converting a Maruti Zen into a sleeping bed!-53.jpeg

My younger brother, who got this entire project executed.
DIY: Converting a Maruti Zen into a sleeping bed!-54.jpeg
DIY: Converting a Maruti Zen into a sleeping bed!-55.jpeg
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Old 9th July 2020, 08:22   #3
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Thread moved from the Assembly Line to the DIY Section. Thanks for sharing!

Now, I want such a bed! Incredible conversion, going to our homepage today
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Old 9th July 2020, 09:58   #4
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Wow - thats quite a lot of effort going into the project & a sweet result! Takes real passion & commitment to take such a project through to end. Most would simply pick a modern designer bed and get done with it! This is a fantastic project.

I hope the Zen now helps in attaining a ZEN STATE while asleep and takes the occupant on enjoyable dream journeys! Thanks for sharing the detailed process along with videos.
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Old 9th July 2020, 10:07   #5
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Wow, this is such a unique and amazing thread! Just shows how such diverse and unimaginable topics can be discussed here

Quote:
Originally Posted by RS90 View Post
Firstly, I am prepared to receive a lot of condemnation from bellow bhp-ians for rendering a loved by everyone and perfectly running good ol zen no more road-worthy.
Not at all! I am sure we all are open minded to recognize the thought process behind this. Also, it's your car - You can do whatever you want with it, and nobody has any right to question it, as long as it's legal. I don't see any ethical issues here too.

I guess this whole project would have probably costed a bomb if it was done outside at a private garage, if at all they agreed to it.

Please post pics of the "storage spaces" too!
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Old 9th July 2020, 10:14   #6
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

wow...the "fun in the car backseat" has been taken to an entirely different level now

BTW, you can probably use the other component parts, like steering column, to make side stands and tables. Those suspension coils can make a wicked table lamp.
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Old 9th July 2020, 12:01   #7
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Straightaway reminded me of this hit song from yesteryears

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Old 9th July 2020, 12:14   #8
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Now this DIY method perfectly fits the requirement for this car suggestion thread started about a decade back.
https://www.team-bhp.com/forum/what-...uld-i-buy.html (Which car should I buy?)
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Old 9th July 2020, 13:07   #9
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Nice job

This was in my bucket list for so many years before I realized I don't have such a big door to bring a car inside the bedroom. How are you gonna handle it? Or this will be placed at outdoors / garage itself?
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Old 9th July 2020, 13:22   #10
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Your creativity has stirred my mind to think about what else!
These are just my wild thoughts , please excuse if they dont sound practical.
I am taking liberty to put my ideas in your thread.

To my eyes this would suit more as a table then bed since the height to climb seems a bit high, but it seems you can use it as both.
How about putting a hydraulic arm ( hatchback door ) to that plywood so that it opens from top as well.

Remove those door from hinges and convert them in to sliding mechanism ( like Kitchen trolley ).
I would have left those door frames as it is and also made some mechanism to put the top on bed when not in use.

Buddy why not some attractive colour scheme?

Aha it seems you can convert that entire Zen in to a cupboard!
Another thing which comes to my mind was to retain the entire structure as it is and just create a flat frame inside the car body which was stripped entirely.You can enter car through any of the doors or hatch and also be able to stretch your legs inside car bonnet.

Would have given a cosy feeling of sleeping inside the car, but would mean you lose on storage.

Kudos to you guys, really well done

Last edited by silverado : 9th July 2020 at 13:28.
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Old 9th July 2020, 15:05   #11
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Fantastic effort ! A good paint job and the whole project will look bomb.
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Old 9th July 2020, 15:20   #12
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Full marks for the effort

But definitely this doesn't look like most of us can DIY
Any reason for taking such long route for getting a Zen State Bed ? I mean considering the efforts involved
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Old 9th July 2020, 15:36   #13
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Great Job brother, really appreciate your effort. You can convert the rest of the items into usable products as well, like the seats could be turned to full-on sofa set and the steering wheel suspension can be turned into a table lamp.
I have a couple of questions, how much does weigh now? and how easy is it to be moved around?
Also, how do plan to bring it inside the house.?
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Old 9th July 2020, 17:24   #14
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Honestly - I do feel sad for the Zen.

BUT - it's better than the scrapyard, and hence - I do understand the thought process behind this project. Engine for brother's college project + body preserved as furniture is far better than scrapping such beauties to be lost forever.

Hope it becomes a dream bed for a kid (or the inner kid) someday.

The new state of rules makes a sad affair for us automobile aficionados - wasting such 10 and 15-year-old cars in working condition just because our car manufacturers want old cars to be scrapped so that people buy more new ones - all under the name of pollution and the environment.

Last edited by CrAzY dRiVeR : 9th July 2020 at 17:26.
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Old 9th July 2020, 19:09   #15
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Default Re: DIY: Converting a Maruti Zen into a sleeping bed!

Can this be called a Sleeper Car?

That's a very innovative idea. Kudos to the effort you're putting on to get this one done. It much satisfying to see the car being used in some way, rather than scraping it. I'm sure a repaint with smoked out headlamps and a few stickers around will make the already hot hatch, look much hotter!!
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