Rusty Rocker Panels (Sill)

1986-1995 : 200TD, 200CE, E200, 260E, 300E 2.6, 300E 2.8, 300E, E320, 400E, E420, 500E, E500, 300CE, E320, 230TE, 300TE, 300D 2.5 TURBO, E300 DIESEL, 300TD, 300E 4MATIC, 300TE 4MATIC, E36 AMG
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Baldrick56
B Class
Posts: 17
Joined: Mon 30 Apr, 2018 2:03 pm
Model you own: w124
Region: New South Wales
Location: Katoomba

Rusty Rocker Panels (Sill)

Post by Baldrick56 » Fri 01 Jun, 2018 8:36 pm

So when I got my 300E I said the verdict on whether it was a bargain or a lemon was awaited:

Looks like its veering more towards lemon. Despite my clambering underneath (as much as you can when it's sat on the road) and looking at all the metalwork the combination of a bumpy drive back home plus (I think) me rodding out the sunroof draintubes has revealed rust around (at least the nearside) jacking points (under a skillfully applied layer of bog). Logic says I should probably scrap the thing, or at least salvage the good bits & find myself a better shell but you know what - I'm obstinate. So day before yesterday I displaced one of the other 'prides & joys,' hauled it indoors, jacked it up one side (not by the jacking points :banghead:) & laid into it with a disc cutter. The rust is relatively localised - around the front jacking point & aft of the rear one, extending into the rear wheelarch. So I've now cut out all the rust on the outer sill, cleaned up & painted the inner sill / wheelarch. Also beaten into (better) shape the passenger footwell floorpan which was a little distorted.
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above are the horrors revealed (interestingly the rear wheelarch section has been repaired before - welding looks passable but little or no attention seems to have been given to rustproofing the internal side :naughty:)

and below after a couple of days attention

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so far 'piece of cake' but (as Basil said) "now for the tricky bit"
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Regards
Baldrick

Fleet:
Mercedes W124 300E 1988 ('Der Valkyrie')
MG ZR160 2005 ('Big Nellie')
Smart 452 Roadster 2003 ('Little Nellie')
Peugeot 505 Station Wagon 1989 ('Louis 505th')
Peugeot 404 Sedan 1969 ('Louis 404th')
Citroen Traction Avant 1953 ('Matilda' - under restoration)
Bristol 401 1953 (under restoration)
That's one for each day of the week - I really ought to stop :think:

Baldrick56
B Class
Posts: 17
Joined: Mon 30 Apr, 2018 2:03 pm
Model you own: w124
Region: New South Wales
Location: Katoomba

Re: Rusty Rocker Panels (Sill)

Post by Baldrick56 » Sun 01 Jul, 2018 9:42 pm

Well I think the moral of the story is: if you're an amateur panel-beater on no account start with the rocker section of a W124 :wall:

made the front (more difficult) section first which combines a reverse curve (on plan) with a variable radius curve in section as you run along - took me all day. put in the reverse curve first, which then kept disappearing as I battled with the sectional curve.

Image

Did I make any rookie mistakes? sure I did, got a bit too enthusiastic with the 'shrinking' hammer so the end product carries some scars despite my attempt at 'planishing.' never mind, at least it's the right shape.
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Must also admit I didn't really have a coherent plan for the jacking point recess (other than hit it lots with a big hammer) so left a bit of 'spare' metal in this area.
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when I came to weld in the panel I did get a small amount of distortion - but a spare jack under the front section soon put paid to that.
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Rear section was a lot smaller & without the complexity of a jacking point to incorporate
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though the interior repair panel was larger at the rear
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Anyway not fully complete as yet but all welded in, ground down, little bit of bog to smooth over the panel gaps, and first coat of primer applied. Will need to put in some 'seam sealer' next week to stop the water / spray gaining access to the interior. Need also to have a careful look at the offside to see what if anything needs replacing there.

Happy fixing, Rob
You do not have the required permissions to view the files attached to this post.
Regards
Baldrick

Fleet:
Mercedes W124 300E 1988 ('Der Valkyrie')
MG ZR160 2005 ('Big Nellie')
Smart 452 Roadster 2003 ('Little Nellie')
Peugeot 505 Station Wagon 1989 ('Louis 505th')
Peugeot 404 Sedan 1969 ('Louis 404th')
Citroen Traction Avant 1953 ('Matilda' - under restoration)
Bristol 401 1953 (under restoration)
That's one for each day of the week - I really ought to stop :think:

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