The Zen Modifications Thread

jdr · 11th January 2014, 14:53

Hi,
I have a 2003 Suzuki Zen (mom's car) that is in a very bad shape (and one that has done less than 10500 kilometres in 10 years). We are planning to buy her a new car, but I want to look into the option of rebuilding it by replacing bad parts with new and better technology. That would include changing the wheels, brakes, suspension, clutch, gearbox, rebuilding the engine, etc.

The first thing to know is that I am a noob when it comes to practical aspects of car modification. I'm a software engineer, so any knowledge and understanding I have is theoretical. I need practical advice and guidance. Now assuming that an attempt at rebuild is still worth considering, here’s the things I can figure out that need to be changed.

All the rebuilds that I have in mind for this 10 year old car matter only if the chassis is in good condition.

Q0. Who can I get all of the below checked from?

Q1. How do I gauge the state of the chassis? What all do I need to check?
If the chassis is useable then the first step would be to upgrade the brakes.
Q2. Is it possible to change the drum brakes on the front to disks and what might the costs be?
The tyres also need to be changed (and maybe the wheels can be replaced with alloys)
Q3. What is an appropriate alloy and tyre size upgrade for the Zen?
The clutch is hard to figure out. It’s difficult to know when it engages. Ideally I would like to change the clutch, and reduce the distance it has to engage and disengage. Also, the gear box, while not bad, leaves much to be desired. A short draw for the gearbox would be nice as well, and a synchromesh first gear too.
Q4. Is it possible to change the gearbox and clutch without changing the engine and what might the costs be?
The next and final step for the first phase is to gauge the engine. IMO the engine is not bad, might need to get better sparks and get it cleaned (flushed) once. But I need to figure out if that’s enough or does it need to be rebuilt as well.
Q5. How can I figure out if the engine is in good condition or needs to be rebuilt and what might the costs of rebuilding be?
Q6. Will a 1.2l K-series engine with its standard transmission fit in the bay of the 2003 Zen? What will a new engine and transmission cost (individually and together)?
I am not too sure about the suspension, but for the sake of consideration, let’s assume we need to change those as well.
Q.7 How much might new suspension cost? Should I stick with the stock suspension or will that change depending on the tyre/wheel setup? If it changes, what suspension should I go with and what might its cost be?

I should also like to install central locking with keyless entry. That should be possible without changing too much of the doors, right? Sundry changes might involve getting a better steering wheel, an audio system (which the car doesn't have), a tachometer added to the dash if not too expensive, and definitely an ORVM for the left side.
The final step is to repaint the car. Nothing extravagant there, colour preference priority goes to mom. Might go in for body-coloured bumpers as well.
I obviously need to get all of this checked from a professional just to figure out whether it’s worth it.
Here’s the thing: buying a new car for my mother is the simplest way to end her car woes. But I am (or would like to be) and enthusiast and so the prospect of rebuilding a lovely Zen (oh so much better than the Estillo) excites me even more than the new Hyundai i20 I just bought (will give owner’s review in a few months).

So I would like to have your opinions on this car and the rebuild potential and the costs involved. The project has to cost considerably less than a new Hyundai Eon or the Alto 800 (that I'm trying to convince her not to even look at). Please let me know what you experts think.

Thanks,
jdr

zenren · 11th January 2014, 22:29

Quote:

Originally Posted by jdr

Hi,
I have a 2003 Suzuki Zen (mom's car) that is in a very bad shape (and one that has done less than 10500 kilometres in 10 years). We are planning to buy her a new car, but I want to look into the option of rebuilding it by replacing bad parts with new and better technology. That would include changing the wheels, brakes, suspension, clutch, gearbox, rebuilding the engine, etc.

...

Q2. Is it possible to change the drum brakes on the front to disks and what might the costs be?

Zen already has disc brakes in front. Or was there a stripped down base variant without disc brakes in 2003? I had spent close to 10k for the brake system overhaul a few years back. So replacing all parts including discs might come somewhere around that figure.

Quote:

Originally Posted by jdr

Here’s the thing: buying a new car for my mother is the simplest way to end her car woes. But I am (or would like to be) and enthusiast and so the prospect of rebuilding a lovely Zen (oh so much better than the Estillo) excites me even more than the new Hyundai i20 I just bought (will give owner’s review in a few months).

So I would like to have your opinions on this car and the rebuild potential and the costs involved. The project has to cost considerably less than a new Hyundai Eon or the Alto 800 (that I'm trying to convince her not to even look at). Please let me know what you experts think.

Even after all the changes you do to your car, it'll still be a low slung, non-PS car with a very high turning radius. Considering it is a car for your mother who I assume would be 50+, the exact opposite might be what they prefer. I would recommend buying her a new car. BTW, Zen doesn't have a high resale value and hence you can probably keep it as a project car.

My mother stopped driving after she retired, primarily because she was not comfortable without the power steering and the high turning radius combination of Zen. For Swifts, she says its too bulky for her to handle in the narrow roads in Kerala.

At their age and considering the current traffic and parking congestion in the cities, some of the most important parameters you should not compromise are the following, based on my mother's views:
Power Steering - a must!
High seating position - they wouldn't appreciate having to bend down to get in and out of the car sooner or later.
Low turning radius - really helps take U turns easily in traffic after a short trip to a near by store in the main road.
Central locking - at least manual central locking. They just don't want to check all doors every time they lock the car or having to stretch to unlock other doors once they open the driver door.
Power windows - Not used normally but this really helps cool down the car after being parked in the sun for a while.
Narrow car - They prefer to be within their side of the road even when overtaking a 2 wheeler - something we can do in Zen but not in Swift.

mints21 · 11th January 2014, 22:52

I agree with zenren. You should buy a new car for your mum and keep the existing car for your experiments. However, changing the engine of the earlier version with the new K-series will be very costly and may not be feasible.

My suggestion would be not to waste too much money in restoring the car and go for a car that your mother would feel more comfortable to drive. This will give her more comfort, convenience and peace of mind. The reliability of the existing car even after restoration will always be a gamble.

jdr · 12th January 2014, 01:13

Quote: