Honker 2000 2N - Wojas

Before (2015) and after (2020,)....

Honker 2000 2N from December 2003. - The car after a major overhaul work on restoring it to factory condition and improving it continues with varying intensity still from September 2015 . 

Auto po remoncie do obejrzenia – >>TU<<

The first, major overhaul was done in late 2016 and early 2017, however, after the season in 2018, the car again went to the body shop to replace the skin parts that were repaired only locally the first time. They say that the appetite grows as you eat, so the owner decided to replace these elements despite the fact that the car looked very good. A plan was adopted to bring the car to factory condition(with some corrections), so we decided that the body could not be patched.

Currently (October 2020) the honker is again in service, this time at our group colleague Przemek, who even with incredible accuracy improves what could still be improved and looks into where we have not yet looked as part of 5 years of continuous rebuilding and improvements 😉 Photos of the work done by Przemek to be seen below in the section REMONT 2020.

For the moment, this is one of the largest honker overhauls we have carried out. The car was completely disassembled and assembled on new or reconditioned parts. Currently, the vehicle presents itself as brand new. In addition, a lot of additional equipment was installed.


AUTA HISTORY:

Purchased on September 5, 2015. 

Condition on the day of purchase: neglected car, with a power pedigree, registered for two people, Euro3 90KW Andoria engine, has a rear bridge lock(faulty electric actuator), Ramsey REP8000 winch, reinforced rear suspension, sheet metal to be repaired (sills, window frames, doors), almost new GoodYear G90 tires, promising technical condition.... 

Update: October 2020:

From the perspective of 2020, we can add that the sheet metal was in worse condition than we assumed, and the promising technical condition was only promising... in fact, over the past 5 years, literally everything has been replaced or reconditioned in this car. Today the honker is one of the better maintained cars of its kind.


RENOVATION + MODIFICATIONS:

The description of the overhaul of this honker has been divided into stages for the sake of order. Not all stage numbers follow the order of the work being carried out - this is due to the fact that many repairs were carried out in parallel.


Stage 0: Registration

Before the renovation took off, the honker was re-registered for 9 people. For this purpose, the grille was removed at an authorized service center and the factory caissons with benches were installed, followed by a special technical examination at OSKP confirming that the modification had been carried out correctly. This operation, although not easy and quite costly, was only possible because the date of first registration fell before 2007, since when belted, forward-facing seats are required in cars. Honkers first registered after 2007. (the specific date falls sometime in the middle of 2007) and equipped with benches, unfortunately, do not have the option of increasing the number of seats in the registration certificate.

UPDATE: In July 2016, the regulations allowing an increase in the number of seats on the registration certificate tightened. Now the operation is even more difficult to implement - no one in our group has yet increased the number of seats after that date.


Stage 1: Sheetmetal (Approach one, second below).

The sheetmetal overhaul involves replacing all the doors, window frames and fenders with brand new ones, after cataphoresis. Sills will be repaired, and new caissons (rear bench bases) will be reworked so that access is under the benches instead of the standard external storage compartments.


Step 2: Remove the body, prepare the frame for sandblasting, prepare the body for painting.

After receiving the car from the tinsmith, the body was removed. The frame was thoroughly washed and delivered to the sandblasting plant. The body will be taken apart, thoroughly cleaned, and finally it will be preserved from underneath.


Stage 3: Sandblasting, painting and armoring the frame.

The frame was sandblasted and painted. One of the body cushion mounts was cracked and needed repair. The radiator hitches also needed repair. Quite a few suspension components, as well as bumpers and steps, were sandblasted and powder coated. A number of components were replaced, such as hoses (including brake lines), cushions (including reducer, body), and the exhaust system.


Stage 4: Body maintenance.

Before the body was put on the refurbished frame, its underside and components such as doors and fenders were treated with a special preservative.


Stage 5: Embedding the body on the frame and transporting it to the service center where the car will be completed.

The body is finally back on the frame! Everything has been connected and the car is "running" again. Honker on a trailer went to a professional service, where it will be painted and assembled, and extensive mechanics will be completed. From here the honker will already leave like new from the factory 😉


Stage 6: Body painting.

Varnishing has taken off! Polyurethane paint RAL6006 (semi-matte) has been chosen - the same that the team's Star 744 was painted with. Varnishing, as you can see in the photos, is done in professional conditions.

UPDATE: After 2 years of use, it turned out that the paint was a dud because it was very susceptible to scratches and heavily faded by sunlight.... 


Phase 7: Mechanics (2015-2019).

Repairs done so far (at least the ones I remember about 🙂 ):

  • replacement of the complete exhaust system
  • Replacement of the fuel system (including fuel tanks, fuel level indicators rigid and soft fuel lines, fuel filter with housing, sealing of the tank valve)
  • replacement of the cables of the drivetrain response system
  • Replacement of most parts of the brake system with new ones (original calipers, discs, pads, drums, stiff and soft hoses)
  • Replacement of suspension components (bushings, rod ends, tie rods, etc.).
  • replacement of shock absorbers with their bases
  • injector regeneration
  • adjustment of the injection pump (injection angle adjustment)
  • replacement of glow plugs and control relay
  • replacement of the alternator and starter with new, original ones
  • replacement of the intercooler with a new one
  • replacement of the cabin heater
  • vehicle after replacement of clutch, valve train
  • drive shaft support replacement
  • replacement of body cushions
  • Replacement of engine cushions twice - the first time the cushions were replaced in 2016 and a MaxGear brand product was used then. To put it mildly, they did not live up to expectations so original, new Mercedes brand cushions No. "A 601 240 07 17" were fitted.
  • gearbox cushion replacement
  • replacement of reducer pads
  • replacement of double-joints with new ones
  • replacement of all filters and operating fluids
  • Replacement of most of the rubber hoses and under hood zip ties
  • Replacement of the paper tubes distributing the blower air around the cabin with stronger aluminum-plastic ones
  • replacement of numerous relays (microcontrollers)
  • professional driveshaft reconditioning
  • Replacement of transmission drain plugs, oil pan, bridges
  • Handbrake repair (replacement of virtually all components including the rod)
  • replacement of the rear bridge lock actuator with a new one
  • replacement of the reservoir and washer fluid pump
  • clutch thrust bearing replacement
  • professional regeneration of the reducer 
  • replacement of air filter housing
  • replacement of fuel filter housing

Step 8: Fitting additional components.

Many additional pieces of equipment will be added... Here are some of them:


Stage 9: Sandblasting and powder coating of components.

Components such as bumpers, piping, rims, tubular sills, seat and bench frames, among others, will be sandblasted and powder coated. In addition, the same treatment will be given to bought/added items such as the tubular spare wheel base, lamp and turn signal covers, and antenna base. Special rubberized anti-slip pads will be installed on the side sills instead of corrugated sheet metal.


Stage 10: Regeneration of the winch.

The winch, after 12 years of use, was in working order, but it worked with marked resistance and looked very unsightly. After disassembly, it turned out that one of the slide bearings was completely damaged, so both were replaced. The winch was cleaned, painted, a new rope and hook were installed, and a wireless remote control was added.


Step 11: Modify the meter.

Anyone who has driven a 2000 honker knows that the meter is underpowered. First of all, it does not have a tachometer and on sunny days it has a completely invisible icon backlight. My meter was modified to eliminate these inconveniences - this modification will be described more extensively in the WARSZTAT section. In addition, I have modified the illumination of the air vents control panel, it has an LED backlight that dims along with the counter illumination.


Stage 12: New upholstery and covers.

The upholstery of the seats and bench seats will be made from scratch. New covers will also be made for the winch, roof searchlight, rear spare wheel, road priorities and a new winter air intake cover. All of this will be made of green cordura 1000. The seat and bench frames have been sandblasted and powder-coated. The steering wheel has been upholstered in leather.


Step 13: Regeneration of the dashboard and other interior components.

The dashboard and other "plastic" components were disassembled and were reconditioned. A large number of components have been replaced with new ones. By the way, the air distribution tubes for the air vents will be replaced - the factory paper ones will be replaced with aluminum ones.


Stage 14: Gathering necessary parts and minor work to be done before assembling the car.

Although the car will not be assembled for some time yet, a number of parts that will be necessary during this stage of the work are already being completed. In addition, holes are being drilled in the bodywork for additional equipment (end pieces, Notek trail lamp, canister holders, etc.) and other minor work is being done.


Step 15: Assembling the vehicle

The first, for the time being minor works have started. At this stage, the individual components of the car are being assembled.

Minor works:

 

Essential Folding:

 

Interior Folding:


2018/2019 RENOVATION: 

As the appetite grows with food, two years after the first overhaul, the decision was made to bring the body to factory condition... This time we approached the subject uncompromisingly and replaced all the components that in 2016 were qualified only for spot repairs. After the full restoration of the body, the car was repainted.

In addition, as part of the renovation, all plating such as piping, trimming, rear steps, sill plates, bumpers, etc. will be replaced or refreshed.


UPDATE 25.10.2020

REMONT 2020: 

The final stage of bringing the honker to factory condition (although frankly we are struggling to make it a little better 😉 ) is an extended visit to the honker in Tułowice at the honkerteam "ASO" run by our group mate Przemek 🙂

This time, all identified childhood ills will be removed, Przemek will look everywhere that has not yet been "looked into" (even if there were no indications to look there) and will realize several improvements. So, this round of renovations can be called putting the proverbial dot over the letter "I" 🙂

Within the framework of the stay in Tułowice will be implemented:

  • Replacing the timing gear including the water pump,
  • Setting up the just-installed new, more powerful Bosch injection pump (adjusting the injection angle, etc.),
  • Engine sealing and thorough cleaning,
  • valve lash adjustment,
  • review of the power steering system,
  • Inspection of the brake system and replacement of some components (e.g., rear brakes, brake lines),
  • Remanufacturing of drive bridges including, among other things, replacement of half-shafts in the rear bridge,
  • Replacing the fuel filter base (restoring the factory solution),
  • Preparing for installation, minor modifications and refreshing the original piping from the 2016 factory showpiece - this piping was dedicated to the so-called "non-German Scorpions" and was adapted for ramming obstacles,
  • Replacement of the tie rod ends (the previous ones lasted 2 years...),
  • Replacing the jaw hook with a newer model,
  • Other minor work...
  • CDN

Work is still in progress so the gallery will be updated on a regular basis