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Dunno how big is the storage capacity from the top of my head. But it might be wise to attach an extra storage to it.
Also - this needs some confirmation/testing but I suspect the older the vehicle is the more and faster wear and tear it is accumulating?
The repair stations have materials and they have attached storage for materials, they are well supplied.
Default is 50% which i have only reduced, so why would repair start at any % significantly higher than the threshold value?
Does not explain why repair would stop while the vehicle still has like 30% or more wear and tear. << this i think is the core of the issue; either it is by design (possibly supposed to happen to older vehicles) or it is a bug.
The older a vehicle is, the higher their minimum attainable wear-and-tear % gets, so that eventually they become in effect unrepairable?
A some time point, you will have to replace the vehicle.
There is a time component, even (used) vehicles in storage for containers/vehicles will accumulate wear & tear. The other part is probably something [delta odometer] times speed with some factor.
For your issue:
If you mouse over the repair button of the vehicle in question during or before its repair then the tooltip will tell you how much wear and tear it would have after the repair.
Then there is a checkbox in the workshop "cancel repair if waiting to long" or something like that, make sure you set the thing you want (aka never cancel anything, let the repair finish).
I have run like 30 years with even some used vehicles from the start and repaired them when above 10%. All get to 0% every time. Just little tedious to set them to 10% whenever a new vehicle is bought. Maybe 20% works as well, but then the repair requires steel as well as mechanical components, so to save on some logistics I opted for 10%.
I had not set the threshold very low (currently 30%) because i figured it would mean vehicles will be repaired very often and increase the number of vehicles that need to be repaired simultaneously, maybe too much for my repair stations to handle. It's interesting that with a low enough repair threshold repair never needs steel and apparently vehicles can be kept in operation for a very long time.