Konrad, a tale of rust and Woe...

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Mercmad
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Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 12:32 pm

Some of you will see that phil over in the desert contry has shipped his 300SE lang to me to be rust repaired .
IMG_0054.JPG
Apart from looking a little tired and some obvious rust it didn't look so bad. A crunch right front appeared to be the only accident damage.
IMG_0055.JPG
The left rear quarter was rusted out as was the whole chassis section under it
IMG_0053.JPG
So,In the meantime i thought i mkight get it running and see if the mechaincal side was OK.
IMG_0056.JPG
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Re: Konrad, a tale of rust and Woe...

Post by Bartman4800 » Mon 07 Dec, 2015 1:02 pm

and and and....???


TELL US MORE BIG SMURF! :laughing6:
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Re: Konrad, a tale of rust and Woe...

Post by brother benz68 » Mon 07 Dec, 2015 1:26 pm

Onwards and upwards
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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 1:44 pm

The Sills had the usual rot so nothing unexpected there.
IMG_0057.JPG
IMG_0055 (1).JPG
On a 300SE the sills are cvered with an Alloy trim whuich tends to disguise the worst rust.On the left rear Rust was visible but under the PVC coating there wasn't any steel left...
IMG_0056 (1).JPG
All the jack points were rusted away completely.Someone has tried to lift the car on them...not a good idea.
IMG_0057 (1).JPG
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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 1:50 pm

Another shot on the left hand inner wheel house at the back. Shows where the rust can enter via the wheel house .
IMG_0060 (2).JPG
Bottom of the left rear quarter. in this case it's a waste of time patching it,it's easier to replace the bottom of the boot box .
IMG_0061 (2).JPG
Strangely enough the drivers side is OK.
IMG_0063 (2).JPG
The bottoms of both rear doors were badly rusted out.
IMG_0065 (2).JPG
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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 1:56 pm

Inside the left rear corner the floor wall was also reusted away.
IMG_0075 (1).JPG
Rust estended into the wheel house itself too.
IMG_0059 (2).JPG
So with the car up on the hoist the time comes to get stuck in and start removing the rotten parts.
IMG_0100.JPG
With fancy sill covers off ,the amount of rot becomes apparent.
IMG_0088.JPG
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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 2:01 pm

This hokey looking weld is in fact the 100mm join where the factory installed a peice to suit the longer wheel base.
IMG_0087.JPG
Cutting away the rust reveals the extent of the damage
IMG_0086 (1).JPG
The outside of the sill is removed and even more rust is uncovered.
IMG_0089 (1).JPG
The the rear quarter is cutv off around the welds .
IMG_0083 (1).JPG
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otr002

Re: Konrad, a tale of rust and Woe...

Post by otr002 » Mon 07 Dec, 2015 2:04 pm

Ok I've bought my ticket to watch this show, wait, I'll be back in a sec, forgot the popcorn! No popcorn! So a beer instead :occasion5:

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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 2:06 pm

The rusty pasrts of the wheel house are removed and replaced with new metal.
IMG_0087 (1).JPG
IMG_0088 (1).JPG
new sections of the chassis need to be fabricated to repair some that has rusted away completely then welded into place.
IMG_0080 (1).JPG
IMG_0077 (1).JPG
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Re: Konrad, a tale of rust and Woe...

Post by konrad » Mon 07 Dec, 2015 2:12 pm

This is better than any Hitchcock thriller. Could be the basis for a Hollywood blockbuster.
Thanks Ron.

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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 2:15 pm

The front was even worse with most of the front of the chassis rail rusted away.
IMG_0082.JPG
A new inner chassis rail made and the new jack point welded into place ,followed by the outer sill cover and end cap.
IMG_0082 (3).JPG
The bottom of the A pillar was also rebuilt .The left rear door and a used rear quater frrom Bartman were mocked up to ensure everything was going to fit right again. Notice the new wheel house sections are in place,bering etch primed and zinc primered before painting and so on.
The rear sill half was just sitting there to guage the fit etc.
IMG_0083 (2).JPG
The paint was stripped off,the new boot box floor is welded into place and the Quarter panel was welded into place followed by the reapir patch panel for the bottom where it was full of filler .There were a few dents in the 1/4 panel to fix but these came out easily.
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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 2:21 pm

yes the door is a new old stock item...Amazing!!.
IMG_0085 (2).JPG
The drivers side is fairly bad but thankfully it is mostly in the front .
IMG_0084 (3).JPG
The cowl is going to require a lot of work to sort out.
IMG_0084.JPG
So i got stuck in and did the sills and the jackpoints,A pillar and inner assis rail first.
IMG_0083 (3).JPG
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Re: Konrad, a tale of rust and Woe...

Post by scoot » Mon 07 Dec, 2015 2:26 pm

Amazing work! In the states I don't think someone would take on the project as it would be cost-prohibitive.
Currently: 65 250SL, 63 220Sb, 65 300 SE lang, 71 280SE parts car

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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 2:28 pm

The front of the iner guard is OK,but the bottom part has rusted away,exposing the air cleaner which had to come out ,plus the boostyer and master cylinder.
IMG_0085.JPG
IMG_0086 (3).JPG
There is a lot of difference in the way these 300's were assembled compared with a regualr W110 or W111 . For instance,this is the inside of the left front guard. it has PVC lining all over the sinside,whereas a W111 would only have a quick splash around the top and the front .
IMG_0089.JPG
The two new rear doors may have looked OK but were covered in a mix of old black etch primer and surface rusat from being in storahge forever. i immersed them in my derusting tank and cleaned them back to bare steel.Followed by a dose of Deoxidine . next step is etch primer follwed by a few coats of primer.
IMG_0089.JPG
IMG_0090.JPG
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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 2:35 pm

once the brake booster was out ,the full extent of the rust under it was revealed. This happens when leaky brake Mastrer cylinders dribble brake fluid onto the paint,removing it and then rust attacks. This whole section will have to be replaced with a fabricated peice.
IMG_0093.JPG
And this is the hole from the inside where thwe aircleaner mounts.
IMG_0095.JPG
While I was driving this car in and out of the shed ,I couldn't get the idle to comwe down,even with then engine up to running temp. Once i got the booster out,all was revealed, a vacuum leak and a half!!.
IMG_0092.JPG
The brakes were non existant anyway and the M/C was also rusted ...
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Re: Konrad, a tale of rust and Woe...

Post by KimB » Mon 07 Dec, 2015 2:48 pm

Good grief!

And you're doing all this work for a couple of slabs of your favourite beer? :laughing6:
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Re: Konrad, a tale of rust and Woe...

Post by pastelgrey300D » Mon 07 Dec, 2015 3:00 pm

Great pics, lots of work ahead but she is in good hands. Where the hell did you find spare doors? Rust free rear Finnie doors are hard enough to find, let alone LWB doors! Hope you're keeping the old ones!
David
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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 3:21 pm

I did a deal with phil on a car to cover the costs :coffee2: because i dont drink. (i'm allergic to alchohol,it makes me dizzy..... :occasion5: ) .Most of the panel work so far is very straight forward but my mig has blown up so that has held me back a bit . It's the restoration of the side trims that going to be difficult but i will cross that bridge later.
The doors came from Melbourne and i reckon they were only NOS left anywhere.

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Re: Konrad, a tale of rust and Woe...

Post by eddie » Mon 07 Dec, 2015 3:24 pm

Very nice work Mr Mercmad, snap on the master cylinder area!! post as much detail of your repairs in this area as humanly possible!!!!
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Re: Konrad, a tale of rust and Woe...

Post by AMG » Mon 07 Dec, 2015 3:30 pm

Nice Going Ron.
Will be up to see it in a couple of weeks :D
Current:
1987 560SL 4sp. auto Signalrot "Stella"
1987 190E 2.3-16 5sp. man. Blauschwarz "Hermann"
1992 300CE-24 6sp. man. Perlblau / Iceblau "Gretel"
1992 Range Rover Vogue SE 4sp auto Ardenne Green "Oswald"
2012 Renault Sport Megane RS265 Trophy 8:08 6 sp. man. Liquid Yellow "Jean Rédélé"
Previous:
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1987 190E 2.6 4sp. auto Signalrot "Sabine" - which now resides/owns Andrew M's Garage
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Re: Konrad, a tale of rust and Woe...

Post by Bartman4800 » Mon 07 Dec, 2015 4:25 pm

Great job Ron,

makes us all look like amateurs... :boohoo:
and makes my Finnie look like one that has a bit of cracked paint and a ding or two..

Good to know that rear quarter scrubbed up ok.

Bart
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Re: Konrad, a tale of rust and Woe...

Post by T-Modell » Mon 07 Dec, 2015 6:33 pm

Hats off Ron! When did you start that work?

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Thomas
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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 6:52 pm

A few weeks ago. Phil came oveer and gave me hand for week to get the doors and so on off. :joker: The fuel tak is full of somwething,which looks like it could the dehydrated remains of petrol .After Christmas i'll cut the tank open and clean it out .The 300 has it's own tank which is different to W111 and W108's. In the USA it was common to fit 6.3 tanks to extend the driving range but those are NLA now. As for the rotten booster,I am sure i have another in the spares department of the same type .The master cylinder will need rebuilding as i'm sure it's unique ( has only two outlets ) Which is going to be interesting because it's rusted solid.

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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Mon 07 Dec, 2015 6:59 pm

eddie wrote:Very nice work Mr Mercmad, snap on the master cylinder area!! post as much detail of your repairs in this area as humanly possible!!!!
OOOh! Eddie ,that loooks really bad! I'll start on making the new peices soon. With that rusty chassis rail you will need to buy a peice of steel the same thickness ( I use Zincanneal) . The big secret to fixing rust like this is too make the peices BEFORE you remove the rotten parts. I also use CAD ...card board aided design . get a couple of sheets of thin cardboard from the news agents and practice making patches . Then you can use the best ones for patterns. With really curvy parts ,as on the W112 ,the easier stuff to use is brown masking paper . That bowl shape under the booster on a W112 is different shape to W111's etc being a touch bigger.

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Re: Konrad, a tale of rust and Woe...

Post by konrad » Mon 07 Dec, 2015 7:40 pm

I also use CAD ...card board aided design . :laughing6: ha ha very good

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Re: Konrad, a tale of rust and Woe...

Post by konrad » Mon 07 Dec, 2015 10:22 pm

Just a footnote to the story; When I first saw Konrad (seems that's the name now) with all of the rust exposed, I suggested to Ron that we "take it to the tip". He said that "it wasn't that bad" and the he had seen worse!! Worse ??? I am in absolute awe of what Ron has done. Absolute awe and am looking forward to going back in mid January to see progress. I must say that I am greatly comforted by the pics which Ron has posted today and commit myself to naming my next child after him. That is if my vas re-connects and I can find a still fertile and willing woman who digs old guys.

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Re: Konrad, a tale of rust and Woe...

Post by T-Modell » Mon 07 Dec, 2015 11:08 pm

What is a "vas"?
Thomas
---------------------------------------------------------------
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1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18
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Re: Konrad, a tale of rust and Woe...

Post by 70499 » Mon 07 Dec, 2015 11:33 pm

T-Modell wrote:What is a "vas"?
Thomas
Vasectomy
Brad.

1958 L319.

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Re: Konrad, a tale of rust and Woe...

Post by T-Modell » Mon 07 Dec, 2015 11:37 pm

70499 wrote:
T-Modell wrote:What is a "vas"?
Thomas
Vasectomy
Thanks, I didn't want to be impolite, I just never heard of that abbreviation
Thomas
---------------------------------------------------------------
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1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18
1986 R107 500SL, arctic white, the midlife crisis viagra replacement
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Re: Konrad, a tale of rust and Woe...

Post by harryskater_220 » Tue 08 Dec, 2015 5:29 am

Awesome Work Ron! keep the pics coming. what is that im looking at in your pic where the front left guard is removed and the end of the sill is all rusted out. on the LH side of the pic it looks like a tank or sumthing?

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Re: Konrad, a tale of rust and Woe...

Post by Bartman4800 » Tue 08 Dec, 2015 11:43 am

The pressure vessel for the air suspension harry.


Bart
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1960 220 Sb Sedan "Zum Schlachten" (Early German Assembly, with a torsion bar spring for the bonnet) - Stored in Country WA
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Re: Konrad, a tale of rust and Woe...

Post by harryskater_220 » Tue 08 Dec, 2015 6:27 pm

oh right! I thought it may have been but the front is on springs also? or converted to springs?

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Re: Konrad, a tale of rust and Woe...

Post by Bartman4800 » Tue 08 Dec, 2015 8:14 pm

Phil's car has at one time been converted to steel springs, they must have left the bottle there.

I believe he has all the gear to revert it back to original condition.


Bart
1963 220 Sb Sedan "Kermit" (Australian Assembly)
1960 220 Sb Sedan "Zum Schlachten" (Early German Assembly, with a torsion bar spring for the bonnet) - Stored in Country WA
1981 Subaru Brumby 1.8 with Weber and 5-speed box "little utie" - Sold to another enthusiast!
2006 Ford Focus "missus car"
2002 VW Passat V6 30V Station Wagon (my new commuter bus)

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Re: Konrad, a tale of rust and Woe...

Post by konrad » Tue 08 Dec, 2015 10:28 pm

Thomas,

"Vas" in this context means "vas deferens" which is the "spermatic duct of testicle". Therefore a vasectomy is the cutting of that duct leading to the "firing of blanks".
Didn't you have sex education at your school? We had wonderful lessons provided by other ill-informed students behind the bike shed. As it should be.

Phil

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Re: Konrad, a tale of rust and Woe...

Post by T-Modell » Tue 08 Dec, 2015 11:04 pm

konrad wrote:Thomas,

"Vas" in this context means "vas deferens" which is the "spermatic duct of testicle". Therefore a vasectomy is the cutting of that duct leading to the "firing of blanks".
Didn't you have sex education at your school? We had wonderful lessons provided by other ill-informed students behind the bike shed. As it should be.

Phil
:laughing6: yes I had to learn it the hard (!) way too ... but I can assure you, I haven't started golf yet :laughing6:
Thomas
---------------------------------------------------------------
1967 W111 250SE Cabriolet, horizon blue
1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18
1986 R107 500SL, arctic white, the midlife crisis viagra replacement
2007 R171 SLK350, calcit white
2008 S211 E63T, calcit white, sleeper

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Re: Konrad, a tale of rust and Woe...

Post by ben108 » Wed 09 Dec, 2015 6:08 am

Great pics thanks Ron.
What chem do you use in your de-rusting tank?
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Re: Konrad, a tale of rust and Woe...

Post by Tazzieman » Wed 09 Dec, 2015 2:43 pm

I wouldn't be game to go near a car with that much corrosion!
Is it an Oz delivered car , and if so was it used for towing boats out of the sea?
Hats off to the man with the magic wand :notworthy:

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Re: Konrad, a tale of rust and Woe...

Post by konrad » Wed 09 Dec, 2015 3:40 pm

"Hats off" ??
Canonisation, at the very least.
or perhaps
"Mercmad for PM"
(that'll have the socialists heading for the border)
[

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Re: Konrad, a tale of rust and Woe...

Post by Tazzieman » Wed 09 Dec, 2015 4:13 pm

konrad wrote:"Hats off" ??
Canonisation, at the very least.
or perhaps
"Mercmad for PM"
(that'll have the socialists heading for the border)
[
A new welding mask?
Image

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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Wed 09 Dec, 2015 9:08 pm

Derust tank ...
in the tank it's just rain water ,around 1000 liters mixed with a kilo of washing soda. i have to put more soda in everytime it rains :laughing6: . The effect is just simple electrolysis .I have a dick smith power supply running at 2-4 volts and maybe 2-4 amps. I can forget things in there but if I juice it up to 6 amps a mudgaurd is strippd in 3 days. I just wash off the old paint leaving clean rust free steel. it has to be dried quick smart .I just use compressed air then a dose of deoxydine to stop any further ferrous oxide . if things are forgotten,it doesn't do any harm, it just sits there in susopended animation .... or something.
I dont like the mollasses idea,it stinks to high heaven and attracts flies. One thing it does do though is attract rats,who fall into the mollasses tanks and die. We had one in the resto shop which smelled like old socks and there at least six rats in it.which were all called wolfie for some unknown reason.

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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Wed 09 Dec, 2015 9:17 pm

Tazzieman wrote:I wouldn't be game to go near a car with that much corrosion!
Is it an Oz delivered car , and if so was it used for towing boats out of the sea?
Hats off to the man with the magic wand :notworthy:
it is i think an OZ delivered car , I have been meaning to get the data card from MB to get an idea of where it was sold new. The rust is actually pretty mild for a finny. The Floors etc are perfect .. OZ built finnys will rust everywhere because they weren't dipped in primer like the German and South African ones were. i did one that was sold new n Namibia (Africa) that was seriously rusted out and required a lot of work to even begin to look right ( the car had sagged in the middle) .Sometimes it doesn't pay to repair them :laughing6:

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Re: Konrad, a tale of rust and Woe...

Post by konrad » Wed 09 Dec, 2015 10:22 pm

Hey Bartman,
Explanation of the science please.

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Re: Konrad, a tale of rust and Woe...

Post by Bartman4800 » Thu 10 Dec, 2015 10:48 am

What Ron means is this (methinks):

The factory in Port Melbourne did not have a paint bath where the assembled bodies are submerged to coat all the hollow sections internally (before being painted further onwards).
They did spray a lot of primer on the places that could be reached though.
So the rust starts on the inside, and only shows when a blister or hole appears.

Interestingly though, my European assembled Finnie that spent most of its life in NT is far more rotten than my Oz assembled one.

Kermit has been a venue car, so probably did not spend much time in the rain. And the NT is humid with lots of iron oxide on the road, which propagates rust as well....


Bart
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Re: Konrad, a tale of rust and Woe...

Post by scorchi0 » Thu 10 Dec, 2015 11:40 am

Mercmad wrote:
Tazzieman wrote:I wouldn't be game to go near a car with that much corrosion!
Is it an Oz delivered car , and if so was it used for towing boats out of the sea?
Hats off to the man with the magic wand :notworthy:
it is i think an OZ delivered car , I have been meaning to get the data card from MB to get an idea of where it was sold new. The rust is actually pretty mild for a finny. The Floors etc are perfect .. OZ built finnys will rust everywhere because they weren't dipped in primer like the German and South African ones were. i did one that was sold new n Namibia (Africa) that was seriously rusted out and required a lot of work to even begin to look right ( the car had sagged in the middle) .Sometimes it doesn't pay to repair them :laughing6:
Pretty sure it is, and I'd go as far to say it was probably delivered by Diesel Motors.

Oh and look what I just noticed:
konrad.JPG
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1991 S124 300TE - Smoke Silver
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Re: Konrad, a tale of rust and Woe...

Post by ben108 » Thu 10 Dec, 2015 3:04 pm

Mercmad wrote:Derust tank ...
in the tank it's just rain water ,around 1000 liters mixed with a kilo of washing soda. i have to put more soda in everytime it rains :laughing6: . The effect is just simple electrolysis .I have a dick smith power supply running at 2-4 volts and maybe 2-4 amps. I can forget things in there but if I juice it up to 6 amps a mudgaurd is strippd in 3 days. I just wash off the old paint leaving clean rust free steel. it has to be dried quick smart .I just use compressed air then a dose of deoxydine to stop any further ferrous oxide . if things are forgotten,it doesn't do any harm, it just sits there in susopended animation .... or something.
I dont like the mollasses idea,it stinks to high heaven and attracts flies. One thing it does do though is attract rats,who fall into the mollasses tanks and die. We had one in the resto shop which smelled like old socks and there at least six rats in it.which were all called wolfie for some unknown reason.

Thanks Ron.
I have done the same in the past with iron engine blocks.. except 20-30A and a bit of caustic and less time :)

I'm always looking for de-rusting methods, so was curious what you were doing..

Thanks
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Re: Konrad, a tale of rust and Woe...

Post by T-Modell » Thu 10 Dec, 2015 7:10 pm

scorchi0 wrote:...

Oh and look what I just noticed:
konrad.JPG
:laughing6: :laughing6: Next upgrade will be Angela Merkel, person of the year :occasion5:
Thomas
---------------------------------------------------------------
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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Thu 10 Dec, 2015 7:21 pm

I'd never use cuastic ,or that many amps... Ordinary soda ash works exactly the same as caustic because all that is required is an electrolyte. The current doesn't flow through clean water very well which is why the soda is added. I keep the amps low which works fine for me.I've done engines too, especially finny blocks which can be really choked up.

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Re: Konrad, a tale of rust and Woe...

Post by Mercmad » Thu 10 Dec, 2015 7:22 pm

T-Modell wrote:
scorchi0 wrote:...

Oh and look what I just noticed:
konrad.JPG
:laughing6: :laughing6: Next upgrade will be Angela Merkel, person of the year :occasion5:
Thomas
At least it wasn't Al bag daddy or what ever his name is :laughing6: :laughing6:

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Re: Konrad, a tale of rust and Woe...

Post by pastelgrey300D » Fri 11 Dec, 2015 10:01 am

and there at least six rats in it.which were all called wolfie for some unknown reason.
You cheeky bugger!

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Re: Konrad, a tale of rust and Woe...

Post by Brad34 » Wed 13 Jan, 2016 11:38 pm

Good to see excellent progress on the Lang there.

I'm certainly inspired to get stuck into mine, and I guess I'll cope without my doors ;)

And Phil, I'm very glad I've still got the black shell, as my red car is more like Konrad than I initially expected!
Brad

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