Driving on Indian roads can be extremely dangerous, and we have seen multiple examples online showing how reckless driving often leads to accidents. There are even instances where people get involved in crashes because of someone else’s mistake. In such cases, the vehicle often suffers severe damage, and repairing it can be a challenging task. We recently came across a video of a severely damaged Hyundai Verna that was given a new lease of life after a workshop decided to restore the sedan to near brand-new condition.
The video has been shared by Brotomotiv on its YouTube channel. In the video, we see a previous-generation Hyundai Verna arriving at the workshop on a flatbed truck. The car had been severely damaged in an accident. According to the owner, the Verna was hit by a truck after he swerved to avoid colliding with a scooter rider who had stopped suddenly.
The roof, pillars, doors, and front end of the sedan were extensively damaged. Several metal panels were badly mangled. The workshop then began work on the restoration project. One of the biggest challenges in such repairs is restoring the body alignment accurately after fixing the damage.
The workshop ordered replacement parts, including a new roof, fenders, headlamps, bonnet, doors, and several other smaller components. They started by stripping the sedan completely. The interior panels, roof liner, dashboard, steering wheel, and several other components were removed to assess the full extent of the damage.
The technicians then used specialised tools to repair the damaged body shell. They pushed the pillars back into position and straightened them using dedicated equipment. Measurements were taken repeatedly with measuring tapes to ensure that the body panels were aligned correctly. The roof was also pulled back into shape before the outer roof panel was cut off. The electric sunroof assembly was also removed.
The team carefully used a saw to cut through the damaged outer body panels while preserving the inner structural components. This was necessary because the exterior panels had been damaged beyond repair. They also removed the front bumper, bumper stay, and inspected the engine bay for any damage.
Once the damaged sections had been removed, the team installed the new body panels. The new roof, fenders, and doors were carefully positioned, and several adjustments were made to ensure proper alignment and uniform panel gaps.
After achieving the correct alignment, the new panels were welded to the original body shell. Several mechanical components had also been damaged in the accident, and these were repaired as part of the restoration. The workshop then addressed the uneven surfaces on the repaired panels. After removing minor dents and smoothing out the bodywork, the car was sent to the paint shop. It is worth noting that all the new panels, along with the repaired sections, received a fresh anti-rust base coat before painting.
This anti-rust coating helps prevent corrosion over time. The workshop also stripped the original paint from the entire car before applying a fresh coat of primer. This ensured that the new paint would have a uniform finish across the entire body. The sedan was then repainted in its original Phantom Black shade inside a paint booth.
The finished product looked almost identical to a brand-new Hyundai Verna. The owner was so pleased with the quality of the restoration that he also opted for a Paint Protection Film (PPF) coating. According to the video, the entire restoration process took almost a year to complete.
Although the vehicle had suffered extensive damage, it was not considered a total loss. If a vehicle is damaged beyond repair, we would not recommend opting for such restoration work, as its structural integrity could be permanently compromised, potentially affecting occupant safety in the event of another accident.