The Green Beast - or what's left of it

1961-1968: a.k.a "Finnie" or "Heckflosse" models
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eddie
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The Green Beast - or what's left of it

Post by eddie » Thu 25 Feb, 2016 9:50 am

Hey Ozbenzers,

It's been a long time since I posted an update on the green beastie. Long story short, I was having all sorts of running issues so decided to pull the motor out once and for all and do a rebuild, with a lot of help from CraigB we pulled the motor and transmission and I also removed the tailshaft to have it balanced and repaired as I was experiencing a vibration at about 50mph. Once they were out and off at various repair shops I decided to tackle a few rust areas that seemed to be bubbling away under the surface. Anyway, you know the story here, one bit of rust leads to another and before you know it I up to be elbows in body work. I decided to also strip out the interior and send that off for refurbishment, but that wont be happening until later in the year.

So here are a few 'before' photos of what's been discovered, this is my first ever attempt at metal fabrication and welding such thin material, so it has been a big learning curve and I have to mention CraigB for coming around every now and then for a bit of advice and assistance.

It's safe to say that this is not the end of it either, I have purchased new floor pans and spare wheel well floors as these have been poorly repaired in the past, the floor for example have been patched but not actually attached to the rusted out structure. Everywhere I find a patch panel, there is typically a great big hole of rust underneath, the previous repairs simply pasted over the rust and hoped it would go away. unpicking the previous work is as painful and slow as putting on new panels as they have been welded in all sorts of strange ways.
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1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Thu 25 Feb, 2016 10:05 am

couple more progress photos
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1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Thu 25 Feb, 2016 10:11 am

and I've made some 'after' shots of progress to date, I'm finding this very satisfying, but doing it after work and between kids events, I think this is going to take most of this year to complete.

I've messed up the order of the photos, but you'll get the idea
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1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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McGavin
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The Green Beast - or what's left of it

Post by McGavin » Thu 25 Feb, 2016 11:51 am

Nice work. A little bit whenever you get a chance will soon add up.

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Re: The Green Beast - or what's left of it

Post by Bartman4800 » Thu 25 Feb, 2016 2:40 pm

Great work Eddie, looks like you had a very steep learning curve!

Rust repairs on these cars are not easy, but quite rewarding and certainly worth it!

Keep up the good work, and keep us posted with pictures.



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 "daily driver"
2002 VW Passat V6 30V Station Wagon (SOLD - This car into a money pit)
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2002 Mitsubishi Rosa Bus (converting it to a motor home)

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Re: The Green Beast - or what's left of it

Post by T-Modell » Thu 25 Feb, 2016 7:47 pm

Good luck with it, looks impressive, your project!

Regards
Thomas
---------------------------------------------------------------
1967 W111 250SE Cabriolet, horizon blue
1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18/19
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: The Green Beast - or what's left of it

Post by Mercmad » Thu 25 Feb, 2016 7:58 pm

The best way to approach a big weld up like this is to think of the elephant... "how do you eat an elephant? ,,one bite at a time,eventually you will have eaten the whole thing".
how-to-eat-an-elephant.jpg
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Re: The Green Beast - or what's left of it

Post by CraigB » Thu 25 Feb, 2016 9:30 pm

Well done Justin. Great commitment and I remember our early conversations about what might be ok to 'let lie' but you must be pleased to now know what is in there and to get it all right. It will be a great car when you are finished.
Craig Baulderstone
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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Fri 26 Feb, 2016 11:32 am

Ha! so true Mercmad, I use that one with the kids - Dad jokes and all that. I also like 'Dad, I'm hungry'.....'Hi Hungry, I'm Poland' but they don't get it....makes me laugh though


You're right CraigB, it all seemed a bit intimidating to start with, but buying the 'interim' car and getting the confidence to have a go has made it seem achievable. I'm even thinking I'll go back and re-visit that area under the brake master cylinder now that the fenders are off - I can't bring myself to leave those last few dodgy patches there anymore.

I'm hoping to get that inner sill and jacking point back together this weekend so I might have a few more pictures on Monday depending on finding the time....

On the mechanical front, the engine block is clean, bored and decked and waiting for the freshened up crankshaft, new pistons and associated parts to go in, the transmission has had all the seals replaced and filters sorted. I have new rubbers for the subframe and rear suspension, so that would only leave the diff and rear axle to have a go at.

Has anyone used an OZ firm to restore the wood work? I've seen companies in the US but not locally???

Thanks guys, will post up more soon
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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Re: The Green Beast - or what's left of it

Post by T-Modell » Fri 26 Feb, 2016 7:26 pm

eddie wrote:... 'Dad, I'm hungry'.....'Hi Hungry, I'm Poland' ...
You have to change that to "Hi Hungry, I'm Austria", they're closer together now :laughing6:
eddie wrote:...Has anyone used an OZ firm to restore the wood work? I've seen companies in the US but not locally??? ...
I'd really really go for a good recommendation; I don't know about Oz, but here you get it done in a price range from 1.000 to 4.000 Euros (W111 wood) and there are huge differences in quality, especially after 3-4 years.

Do you have pictures from the new floor panels welded in?

Thomas
---------------------------------------------------------------
1967 W111 250SE Cabriolet, horizon blue
1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18/19
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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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Sat 27 Feb, 2016 7:26 pm

Hey Thomas,

No floors in yet, I have to do the structural support and sills first and then prep for the floors, it will be a month or two yet.

Slow going!!
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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Re: The Green Beast - or what's left of it

Post by Jake » Sat 27 Feb, 2016 8:58 pm

Nice work on a nasty job .

Will you spray plenty of cavity wax behind the repairs ? You know , just to prevent an early re-occurrence of the lurgy :)
There is a fine line between hobby and mental illness .

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Tue 01 Mar, 2016 10:00 am

Thanks Jake, certainly trying too, where I can reach I'm preparing and painting, where I can't reach I will attempt to clean and then spray in the cavity wax. I'll give it my best shot to stop any return, but I'm in complex areas/shapes that aren't easy to clean and prepare to 100%

It will still be better than it was!

I managed to fabricate up the inner sill but not fitment, so no photo, maybe later in the week
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Thu 31 Mar, 2016 9:20 am

Bit more of an update. I've managed to install the new sill and jacking point in the drivers footwell along with a few other minor bits in the floor pan. bit of grinding and painting to go...

I've messed the order of the photos up again, go from bottom to top
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1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Thu 31 Mar, 2016 9:27 am

now on to the rear jacking point, this is a complicated area, with a transverse box section at the front edge of the rear seat meeting with a double sill section. Complicated further by the previous repairs that have simply patched over the top of the rust with no attempt to fix the structural problems or rust proof anything. At least the B pillar is in good condition along with the little 'C' shaped bit that holds the rear suspension but almost everything else in these photos is toast.

I dropped out the rear axle to get better access, this will need multiple bits fabricated up, I am having some trouble seeing how the rear wheel arch connects to the out fender panel and the inner and outer sill as the original pieces no longer exist and the patches are a poor replica of what was there. I'm using some photos from the net, but if anyone has the ability to photograph this area from the wheel arch looking forward that would be a great help!!

this bit is going to take me a while as the previous patching is extensive and poorly done, so I've got my work cut out for the next little while
You do not have the required permissions to view the files attached to this post.
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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T-Modell
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Re: The Green Beast - or what's left of it

Post by T-Modell » Thu 31 Mar, 2016 5:41 pm

HI,
don't know what you need exactly, but I've just been in the garage ... does this help?
TK0_7062.jpg
Thomas
You do not have the required permissions to view the files attached to this post.
---------------------------------------------------------------
1967 W111 250SE Cabriolet, horizon blue
1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18/19
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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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Thu 31 Mar, 2016 7:40 pm

Thanks Thomas, just about right, a bit higher up and a bit more inside the wheel arch if that's ok
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Thu 31 Mar, 2016 7:42 pm

Actually looking again, that's the rear of the wheel arch, I'm looking for the front of the wheel arch, and then a bit higher up and a bit more inside :happy3:
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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T-Modell
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Re: The Green Beast - or what's left of it

Post by T-Modell » Thu 31 Mar, 2016 7:46 pm

Something like that?
2013-06-22 - 1323 - Konservierung Halle Heidelberg Teil 1 - Neue Loecher in Schweller fuer Ablauf Wasser_1024x681.JPG
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---------------------------------------------------------------
1967 W111 250SE Cabriolet, horizon blue
1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18/19
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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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Thu 31 Mar, 2016 8:16 pm

That's spot on thanks Thomas, what are u drilling the hole for?
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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T-Modell
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Re: The Green Beast - or what's left of it

Post by T-Modell » Thu 31 Mar, 2016 8:23 pm

eddie wrote:That's spot on thanks Thomas, what are u drilling the hole for?
There were no holes in the sill-bar (as they should have been); so we drilled the holes while conserving the car. In those days quality management wasn't perfect :whistle:

Seriously; if you check the conservation plan of Mercedes, the holes should have been there.

if you need more photos let me know, I've taken quite a few during the conservation process.

Thomas
---------------------------------------------------------------
1967 W111 250SE Cabriolet, horizon blue
1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18/19
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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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Thu 31 Mar, 2016 10:11 pm

Well, i think i will be drilling some holes too. Could explain part of the rust issues I've got.
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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T-Modell
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Re: The Green Beast - or what's left of it

Post by T-Modell » Thu 31 Mar, 2016 10:14 pm

I hope this helps in case you don't have those pics ...
Konservierungsplan W111 C.JPG
Konservierungsplan W111 C Schweller.JPG
Regards
Thomas
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---------------------------------------------------------------
1967 W111 250SE Cabriolet, horizon blue
1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18/19
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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drew56cus
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Re: The Green Beast - or what's left of it

Post by drew56cus » Fri 01 Apr, 2016 7:38 am

Good work eddie, you have grappled the beast and are now twisting and pounding it into submission! Rust, be gone!
Drew
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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Fri 01 Apr, 2016 9:19 am

Thanks for that Thomas, none of those holes in the sills exist, they are not on the top of the sills (which haven't been patched over) and they aren't on the bottom as everything has been cut and covered, several holes to drill I think, which I was thinking about any way to feed in some cavity wax after I'm done.....which will be quite a while!!

I've also sent off the interior to be retrimmed, which is optimistic of me and putting the cart before the horse a bit, but I've told the guy he can take up to twelve months and knowing that bits like that are coming back gives me a deadline of sorts to get on with it.

I've pulled the back axle out of the car and am contemplating whether to fix this myself or farm it out, but can anyone recommend a place in SA that would refurbish it? Olaf perhaps?

It has some big play in it - need to talk to you CraigB to see if you have something stashed away somewhere???
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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Mercmad
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Re: The Green Beast - or what's left of it

Post by Mercmad » Mon 04 Apr, 2016 1:21 pm

mine was similar, maybe a bit more and my firewall wasn't so bad .I cut the entire floor out which was easier than trying to repair the rot. :-) i have some sill sections (outers)which had been bodged onto the car in the past but can be repaired to use as sill parts .let me know if they could be of use.might have the firewall section too.

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Tue 05 Apr, 2016 10:33 am

thanks Mercmad, might need some for the passenger side, the drivers side outer is in good condition. I've got new floor pans to replace the existing, just have to get these sills sorted and then I will have a go at the pans.
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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Mercmad
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Re: The Green Beast - or what's left of it

Post by Mercmad » Tue 05 Apr, 2016 4:44 pm

you can have them both for the cost of shipping if you like . They are ugly but only because of some rather interesting welding. Cleaning them up would be a lot cheaper than buying new ones and the material is so heavy I doubt you would find anyone locally to bend new ones for you .

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Wed 06 Apr, 2016 4:55 pm

thanks Mercmad, will be in touch if required, don't suppose you have a photo kicking around of them?

I haven't got to the shed at all since easter, so this rear section is going to be some time yet!!
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Tue 03 May, 2016 3:12 pm

So I've made a little bit more progress, I'm struggling with the rear jacking point area, very complex shapes and multiple parts to it, also the previous repairs were just wrong, so first time using them as a pattern they didn't line everything up, so onto second set of repair patches. I still have more cutting and shutting to get right but making some sort of progress. I've tacked in a few of the other areas too, just need to get another session in the shed to weld up. I'm almost there with the front end at least!!
You do not have the required permissions to view the files attached to this post.
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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Re: The Green Beast - or what's left of it

Post by Bartman4800 » Tue 03 May, 2016 3:43 pm

Good work, you are getting there!

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 "daily driver"
2002 VW Passat V6 30V Station Wagon (SOLD - This car into a money pit)
2011 Kia Sportage "Missus commuter Bus"
2002 Mitsubishi Rosa Bus (converting it to a motor home)

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Mon 30 May, 2016 3:40 pm

Only a small update, I'm not getting much time in the shed at the moment, a sunday afternoon every other week at best and it usually takes me a little while to remember what I was up to, pontificate for a while and then get on with it!!

I managed to get the rear jacking point installed finally, which means I can move onto the wheel arch, I had to do it in two pieces due to the size of the area (very long) and because the old wheel arch was patched several times on top of each other and it's taken me a while to figure out how best to repair it.

So, here's a few snaps and hopefully a few more of the wheel arch repair coming soon
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1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Tue 02 Aug, 2016 5:05 pm

Few more little updates, it's been slow going, but at least it's still moving in the right direction!!

This rear chassis leg/rear jacking point has really tested my amatuer skills, but happy with the result, I don't have the final photo yet, but it's all closed up again. Now I have to put the actual outer skin back together and that's where my skills probably stop, might just tack the old rusty bit back in and go and see a panel shop for the final finish.

here's a few photos of the rear wheel arch and also fixing up the parts in the engine bay. The engine bay is more or less complete now and I will have to clean it all up in preparation for painting at some point.

Engine bay inner fender:
inner fender progress 1.jpg
inner fender progress 2.jpg
inner fender progress 3.jpg
Rear chassis leg repairs:
Rear jacking point 9.jpg
outer wheel arch repair.jpg
Inner wheel arch repair.jpg
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1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Mon 29 Aug, 2016 11:03 am

Things have escalated, I knew there was some damage to the front clip and with it in place I couldn't fix everything at the very front of the chassis rails and inner fender panels, so decided to pull it out and repair it properly and gain some useful access to front bumper support panel and the front of the inner fenders. the front bumper support was bet backwards by a previous accident and it made fitting the front bumper very difficult.

The previous repairs to the front clip have involved much bad welding and hammering of the sheet metal that subsequently damaged the paint and wasn't put right, so there is rust and allsorts in there that need attention.

I managed to pull the front bumper support forwards to where it should have been so that will make the bumper fit up nicer than it was previously. now to fix the front clip and get it back into the car. This will take a little while, there are some rust patches to weld in (car is going to have more patches that a smokers anonymous meeting) strip the paint, clean up the surface rust, hammer out the manged shape of the panel, fix the support bit under the radiator (needs a new part I think), then a spray and finally put it back in.

And to think I wanted the new floors in by now and I'm still working in the engine bay!!
You do not have the required permissions to view the files attached to this post.
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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Bartman4800
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Re: The Green Beast - or what's left of it

Post by Bartman4800 » Mon 29 Aug, 2016 11:12 am

Nice work Eddie, I know it is tedious but just keep in mind how much you will enjoy having a great car later on!

When you do those hollow sections, do not forget to protect them internally with cavity wax or grease (but after you painted them)
The zinc plated material will certainly make things last a lot longer.

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 "daily driver"
2002 VW Passat V6 30V Station Wagon (SOLD - This car into a money pit)
2011 Kia Sportage "Missus commuter Bus"
2002 Mitsubishi Rosa Bus (converting it to a motor home)

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Sun 20 Nov, 2016 12:35 pm

Hi all
Ive been working away very slowly through the winter. Haven't made a huge amount of progress but still moving in the right direction
Had a go at the floor pan on the drivers side and the front clip. Here's a photo or twoImageImageImageImageImageImageImage



Sent from my iPhone using Tapatalk
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Sun 20 Nov, 2016 12:37 pm

The floor is just loose has to come out again to fix yet more hidden rust inside the chassis box and a cracked seat mount. Getting there slowly!!ImageImageImage


Sent from my iPhone using Tapatalk
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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drew56cus
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Re: The Green Beast - or what's left of it

Post by drew56cus » Sun 20 Nov, 2016 12:37 pm

Now that looks much better! Good one, keep chipping away at it.
Drew
'65 220SE 4.5 Frankenbenz finnie :)
'65 220SE/C (#1 project - Tenorite grey)
'64 300SE/C (#2 project)
'66 250SE/C (#3 project)

Ludwig
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Re: The Green Beast - or what's left of it

Post by Ludwig » Sun 20 Nov, 2016 3:33 pm

This reminds me of the story about the bloke who had the same axe for 60 years.
Only replaced the handle 6 times and the head twice.
1954 W180
1971 W109 300SEL 3.5Litre
1981 W123 280e (2)
1982 W124 230e

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Sat 21 Jan, 2017 7:53 pm

Ok, so the drivers floor pan is finally sorted, I'm moving on to the passenger side. At first glance I had always thought this side was in better condition than the other, but dig a little deeper and it's all bad news. All fixable of course. That's the next few months of shed time accounted for!!

The whole inner sill from the seat to the firewall is rusted out, jacking point almost non existent, chassis leg under the floor is in really good condition though.

Worst part is where the transmission mount is welded to the floor pan. It forms a double skin and this has rusted through. Will be tricky to fixImageImage


Image
Image
Image


Sent from my iPhone using Tapatalk
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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T-Modell
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Re: The Green Beast - or what's left of it

Post by T-Modell » Sat 21 Jan, 2017 9:15 pm

If I pay for a cheap eco flight to Germany with never-come-back-airlines, would you come for some weeks (for free of course) to do my Pick-Up? :laughing6: :laughing6:

Hats off, great work. I could never imagine doing this. Great floor pans btw. :laughing6:

Regards
Thomas
---------------------------------------------------------------
1967 W111 250SE Cabriolet, horizon blue
1973 W115 220D 5.0 Pick-Up Argentina, work in progress 2017/18/19
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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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Sun 22 Jan, 2017 10:11 am

Sure Thomas, no problem, might have to pay for some excess baggage for the welder and gas!!

Need a boot floor next somehow[emoji6]


Sent from my iPhone using Tapatalk
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

merc-304
250s
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Model you own: w126
Location: North Coast NSW

Re: The Green Beast - or what's left of it

Post by merc-304 » Sun 22 Jan, 2017 10:48 am

Mention of boot floor reminded me of Harryskater Finnie resto from NZ..what a brilliant job they did of folding one up.
380 SEC

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Sun 22 Jan, 2017 7:53 pm

Ha, I have looked at every detail of that rebuild about 20 times, I have borrowed a few of the sheet metal repair ideas!! It was great work. Folding a new boot floor is a bit out of my league, would happily weld in a replacement full panel though.


Sent from my iPhone using Tapatalk
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

merc-304
250s
Posts: 267
Joined: Sat 09 Jul, 2016 3:55 pm
Model you own: w126
Location: North Coast NSW

Re: The Green Beast - or what's left of it

Post by merc-304 » Sun 22 Jan, 2017 8:30 pm

Any sheetmetal shop would be able to fold one up for you along with infill pieces for each end.....leaving you to weld up.
380 SEC

CraigB
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Re: The Green Beast - or what's left of it

Post by CraigB » Sun 22 Jan, 2017 11:36 pm

If there is any similarity to W108 there would be a rust free boot floor here you are welcome too.
Craig Baulderstone
Lurch
280s's
280SE3.5
280SL
350SL
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560SEL's

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Mon 23 Jan, 2017 11:22 am

Hey Craig,I hadn't thought of the w108 being similar, but I checked the part numbers online and the boot floor is the same between w111 sedan, coupes and w108's, so that could work.

it's a bit down the track, will catch up with you shortly and have a look maybe
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

CraigB
OZBENZ Admin
Posts: 4854
Joined: Thu 23 Jun, 2005 2:18 pm
Model you own: I own multiple different models
Location: Hawthorndene (Adelaide)

Re: The Green Beast - or what's left of it

Post by CraigB » Mon 23 Jan, 2017 11:29 am

That's perfect. I will have a closer look on condition. Great if it can be used rather than going to the crusher.
Craig Baulderstone
Lurch
280s's
280SE3.5
280SL
350SL
500SEC's
560SEL's

sebada
E Class
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Location: El Pinar, Uruguay

Re: The Green Beast - or what's left of it

Post by sebada » Tue 24 Jan, 2017 12:46 am

Great work Eddie !!! :notworthy:

I feel so identified with you, my coupe is in similar condition, same bad repairs everywhere, I have no bodywork experience but I'm planning on putting my hands to work since I think that nobody will take care of the car as I will do.

I have ordered from ebay a workshop bodywork manual, it hasn't arrived yet but as soon as I got it, I will be very pleased to help you as I can to put the green beast on the road again. :occasion5:

Sebastian

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eddie
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Re: The Green Beast - or what's left of it

Post by eddie » Tue 24 Jan, 2017 9:54 am

Thanks Sebastian,

I have that book too, lots of technical detail and mainly set up for large scale accident damage, but there are a few interesting bits of information on rust repairs of the sills and wheel arches etc.

There is a diagram showing all manner of dimensions for the chassis, which I found a little confusing, so if you can work out the starting point for any of the dimension please let me know!!

All the best with your restoration, it takes time, but I feel is worth the effort
1998 W210 E240 - yawn, but like a tank
1969 Fiat 124 sport coupe - sold it...bit sad but onwards and upwards
2000 Mk4 VW Golf GTi - the german's should be ashamed - SOLD, no love lost there
1965 W111 coupe 220seb
1998 BMW M3 - interim car until the coupe is back, bit of a rocket to boot - SOLD, cant help but think I'm going to regret selling that one :think:
2003 Porsche 911 - had to see what all the fuss was about

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