Update on my Hyundai Sonata V6 restoration: Interior rebuild underway

The delays in getting parts and juggling uncertainties have been the most challenging part of this rebuild, and the expenses, of course.

BHPian ads295 recently shared this with other enthusiasts:

Hey guys.

Thanks for your support. This has been quite the journey.

I paid ₹10k advance (50% of the total) to the scrap dealers in Kerala on 10th August '24. They are yet to ship the parts, putting forth one excuse after another. I lost it Thursday night and told them off, stating that I either wanted the parts to be shipped on Friday or I wanted a full refund of my advance. They were taken off guard and promised to ship everything. Yet they still shipped only half of the parts as of today, the balance are promised to be shipped by Tuesday.

It's quite frustrating and a little scary at the same time because I'm all too aware that they can just block me and carry on with their lives. It's all running completely on word of honour at the moment (even though my previous order with them was executed successfully - I paid 100% advance that time).

The delays in getting parts and juggling uncertainties like these have been the most challenging part of this rebuild (and the expenses of course.) I hope this thread serves as a point of reference to anyone who wishes to undertake a comprehensive rebuild of an old motor that has an unknown history and sketchy spares availability.

Here are a few updates on the car.

Interior rebuild underway

The interior is being put together as we speak. The rear door cards are installed, so is the dashboard and the rear parcel tray. The air purifier's plastics (the body) have become so brittle that I could snap them into two like a biscuit. I have an idea that I'm putting into action to cover the purifier - it's open right now.

The fabric on the door cards has been re-upholstered. The cards themselves have been washed and cleaned with soap.

The floor mats have been thoroughly washed and the pedal area looks nice and clean.

New spoiler is painted and on the car!

Everything in the boot is ready and good to go - the shrouds and covers have all been installed. The rear spare rim and tyre is in its place (full size!)

The CD changer unit will have to go, unfortunately - the changer mechanism wasn't present when I bought the car. I tried my best to source it from scrap dealers but to no avail, since this was available only on the V6 cars (a sub set of an already rare car).

Bonnet sealant applied

What are these black spots, you may ask?

That is the sealant applied between the sheet metal top of the bonnet and the layer below it. Without this, the bonnet would make a twanging sound every time pressure is applied on it, deforming temporarily. The OE sealant had melted away due to heat - either from the environment or the engine. It's refreshed now and good to go. The same application has been done in the boot.

This itself took multiple trials because the purchased caulking gun (local make - costs ₹350) used to apply the sealant was found to be too weak, it simply twisted and deformed when pressure was applied to squeeze out the sealant. My mechanic scoured the market and finally bought a sturdy one that costed ₹650.

Brake calipers are painted

I went with a rather rad shade of blue, and I hope my gamble pays off. The alloys are pitch black so they should set these off beautifully.

Lastly, I present one of the many guardians of the Sonata while the car hibernates.

The glue used to bond the sagging headliner to the roof board literally gives the interior a new car smell. I couldn't help but giggle the first time I stuck my head inside to check out the work.

Onward, and upward...

Check out BHPian comments for more insights and information.