Fixing a rust issue on my 1995 Zen before Mumbai's monsoon

A rusted apron in an Old Maruti Zen or Esteem can literally be the end of the car as it will cause the car to sag to one side.

BHPian BeemerBug_06 recently shared this with other enthusiasts.

With the monsoon finally here, it's time for another update. Thankfully a major issue was averted before it began pouring in Mumbai.

A few months ago, I noticed the car's interior smelt a bit musty like a stack of old newspapers. I noticed it almost immediately because I ensure it is otherwise always smelling clean and fresh thanks to the AmbiPur I use. It didn't take me long to figure out that the smell was due to stagnant water which had somehow made its way into the cabin and was collecting on the carpet by the passenger footwell.

I decided to ignore it for a few days and drive. After a week, the water made its way into the cabin again right after the car was cleaned by the cleaner. It was then that I realised that my car had finally begun to show signs of what I call the "slow death". To confirm, I poured some water directly onto the wiper cowl area, and as expected, it crept into the cabin from behind the dashboard.

The affected area is the firewall, in between the dashboard and engine bay. Water enters it from the cowl panel space and collects, causing it to rust out. The firewall is a very vulnerable rust spot in all Old Maruti Suzuki cars and can cause hell if it's not repaired on time. The rust slowly spreads from there to the strut mount area and then to the aprons. A rusted apron in an Old Maruti Zen or Esteem can literally be the end of the car as it will cause the car to sag to one side. Even if repaired, there's no guarantee that it will be as good again. So I urge all those of you who wish to keep your old Marutis alive to attend to the firewall area and prevent it from rusting as much as possible. If it's already started, fix it immediately.

As I plan to retain the car for as long as I can, I decided to fix it. I asked at a few known places and was given a rather high quote for the repair which did not seem worth it. Finally, the car was dropped off at my buddy Noel's place in Belapur. Those of you hailing from Navi Mumbai would probably know that Noel runs a place called Nelly Auto and does good work at a reasonable rate.

I dropped the car off to Noel on the 17th of June and was told it would be ready within a week if all goes well.

Two days later, I received a couple of pictures from him of the damage.

To my surprise, the rust was not as bad as I expected. However, this was not a good sign either, I thank my stars that it was saved in the nick of time!

Anti-rust was generously applied in the area. Post application, I should not face any trouble for at least the next 3-5 years.

In exactly a week's time, the car was ready and I went to pick it up. Noel and his guys did a very quick and efficient job. Yesterday was a rainy day and I got caught in a heavy downpour on my way back from Noel's. Not a single drop of water made its way into the cabin, hence a job well done

If you are in Navi Mumbai and need someone good and reliable to look into your automotive needs. I would definitely recommend Nelly Auto. Noel is very sincere and will do right by any and every car. Do give him a buzz if needed.

As for the car, I plan to give it a bit of a break in the monsoons but will of course ensure it is driven regularly again post that.

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