W115 Ute Project starts ...

[tsharkey]

Love the SD card slot for your tunes.

I read somewhere that according to Germany's Telecoms Law, all new car radios should be capable of receiving digital terrestrial radio from 21th Dec 2020 – as required by the European Electronic Communications Code. Did you add DAB+ ?

Bluetooth and microphone would complete the install ....

[T-Modell]

Hi Tim,
true, in Germany DAB+ is mandatory for new cars since one or two years.

If you add DAB to an old radio you have to solve the display issue. I haven't found anything with a display small enough to fit in an old cassette slot. Alternatively you could install a retro radio, but I do have a connection to those 80s radios; the Nashville was my very first radio as a university student and it was quite a big investment at the time for me ...

Regards
Thomas

[T-Modell]

Home:


So, after our holiday, I did the final (?) works at Mercedes today. There's still a to-do-list, but - hopefully - nothing major. Did a test drive, still have to adjust the gear shifting and a few other nooks and crannies ... I'll keep you updated!

Regards
Thomas

[tsharkey]

Fantastic - I am sure there will be months of sorting out the little things.

When is the celebratory lunch with the workshop ?

[Christo C]

… burnouts in front of the local picture theatre Saturday night?

[Nabstud]

Good news! I assume it came home under it's own power?

Now we need a pic of you "smoking the rears", the Aussie way to break-in a ute....

[matthewz108]

Congratulations. In the history of car builds followed on a forum, this is definitely the most epic, with a heart wrenching start, longevity, and a nerve racking finish.
I nominate this thread for a full length feature movie.
It at least preservation of the thread for future generations to read...?
But will there be a sequel?

[T-Modell]

Thank you guys,

When is the celebratory lunch with the workshop ?

March/April, as I am waiting for the omikron wave to subside.

… burnouts in front of the local picture theatre Saturday night?

No, I'm just a German old man, no fun in me

I assume it came home under it's own power?

Yep.

But will there be a sequel?

I quote my wife: "No".

Amongst all the little problems, there's only one bigger one. Not in the prototype, but now there is a banging noise (not a metallic noise) when accelerating hard from zero:

1) Car is absolutely vibration and noise free > 25/30 km/h, tested it up to 150km/h so far (it's actually amazing). No problems when starting with less power
2) All parts are new in the drive train
3) Drive shaft is aligned as good as possible
4) One theory: Not enough weight on the rear axle (different to the prototype sedan), so the rear axle hops
5) Motor touching something
6) Something on the rear axle touching

I ordered a cheap action cam to put it in different spots to "see" the noise - hopefully.

Kind regards
Thomas

P. S.: Just a different car with hubcaps

[Christo C]

Could the banging noise be the rear number plate thingy flapping?
Cheap camera a good idea - less risky than strapping Timo underneath during a test drive.

[CraigB]

I've been away for a few days but great to see it home and looking very 'completed' and beautiful

Banging on hard acceleration, my thoughts would be exhaust or something on the motor touching on the side that the torque is twisting it too. Or anything else. Last year the E220 had what I would call a banging and I think it was exhaust manifold onto steering box, on a completely standard car, but only under really hard take off. The engine mounts looked ok when off the car, but replacing with 6 cylinder ones fixed it. The last bit not relevant to you, but just trying to explain how minimal movement created a banging sound.

[AMG]

So Thomas.... You can now say unequivocally:

Been there
Done that
got the

Take a break for a while. Just spend some time in the garage looking over the detail. Take it all in, remind yourself of all the little things

Make notes for that book. It will be an epic read.

[kimrh]

Using a camera mounted underneath will work.
You sure it is not axle hop

Thomas any ball park figure $ on the overall cost of the project out of curiosity
There was a ton of fab work that went into that chassis frame and panels

[Honey500]

Wow Thomas I turn my back for a few short months and you have more challenges in that time then most projects have in their entirety! If this build has shown anything it is that you are perhaps the only person this side of anywhere that could push through and still complete it.

It is great to see it home and close to complete. It looks and is a stunning project!

Cheers to you Thomas

[T-Modell]

Hi guys,
thanks a lot for your compliments, very well appreciated

Well, I guess I was pretty honest with this project and also reported mistakes, wrong assumptions and false directions I took. This one is pretty odd:

In 2018 we tested the prototype, especially regarding vibrations of the drive shaft. Very critical in such a project. Car was absolutely fine.

However, after assembly we heard a rumbling noise when accelerating hard from 0. Over 25/30 km/h it was gone. Thought we tackle that later. Well it wasn't the traction of the rear axle, but the drive shaft is oscillating quite heavily there. One middle bearing was ripped apart already. It turns out, that the angle between the front and rear part of the drive shaft is too big.

I developped an idea and got a used drive shaft from a W126 500SE for "redesigning" purposes (bought it from the "R107 slaughterhouse", where I got the donor car ... that is their name ). Hopefully next week I can give it to the drive shaft specialist here and have it rebuilt ... I'll report then.

Here's a "shocking" video of it (takes a while to load, 130MB): https://tk-pro.de/Pick-up/2022-02-14%20 ... t%20sm.mp4
First acceleration in 2nd gear, second acceleration in 1st gear.

Regards
Thomas

P. S.:

...Thomas any ball park figure $ on the overall cost of the project out of curiosity

Well, I took notes of every 3.99 EUR I spent, because I wanted to know the real cost. Also things like the Diesel for the sprinter to get the motor back and forth is included. I will not tell you the figure, but I think you can guess, that a 5-digit EUR number doesn't cover it. Far too much, but everybody does stupid things in his life. My S-Class W222 was cheaper.

[Nabstud]

Wow, that is some serious movement in the driveshaft!

That video was crap and awesome at the same time - driveshaft vibration and the sound of that motor!!!!

[John Green]

In 2018 we tested the prototype, especially regarding vibrations of the drive shaft. Very critical in such a project. Car was absolutely fine.

However, after assembly we heard a rumbling noise when accelerating hard from 0. Over 25/30 km/h it was gone. Thought we tackle that later. Well it wasn't the traction of the rear axle, but the drive shaft is oscillating quite heavily there. One middle bearing was ripped apart already. It turns out, that the angle between the front and rear part of the drive shaft is too big.

We had the same problem with the very first W123 that we converted to a M117 engine. Exact same issue, a driveline vibration under load an low speed. After much money time and beer we found out the issue was the "phasing" of the driveshaft. It wasn't enough for the tailshaft to be balanced, or for each section to be balanced individually, but it has to be phased. We found a tech bulletin from Holden (remember them) about the same issue with Commodores and it gave a very specific instruction on aligning the uni joint and the yoke for the coupling. I have tried to find it again but can't. I can however confirm that we messed around with the spline one tooth at a time and the vibration eventually disappeared.

[John Green]

My S-Class W222 was cheaper.

Life is like that. Enjoy it for the next 20 years and it is a bargain.

[T-Modell]

Thanks John for the tips,

today - I think - we could solve the problem. It was the drive shaft angle. I just "test-bought" another middle bearing and this changed the angle of the drive shaft in a way, that a test drive was pretty good. Higher speeds than 100km/h still have to be tested, but the acceleration from zero is ok now. Now on to the many little to-do's ...

New video: https://tk-pro.de/Pick-up/2022-02-21%20 ... 0shaft.mp4

My S-Class W222 was cheaper.

Life is like that. Enjoy it for the next 20 years and it is a bargain.

I like your point of view

Regards
Thomas

[pastelgrey300D]

Big improvement on the vibration there, well done.

One of the things I've loved about this build is the insistence on making everything look period correct - you've even managed to set the timestamp on the camera to the correct era! Now that's attention to detail!

date stamp.JPG

[CraigB]

And you know with a comment like that there are people with a very keen eye for detail! Well done Dave!

[Bartman4800]

Thanks John for the tips,

today - I think - we could solve the problem. It was the drive shaft angle. I just "test-bought" another middle bearing and this changed the angle of the drive shaft in a way, that a test drive was pretty good. Higher speeds than 100km/h still have to be tested, but the acceleration from zero is ok now. Now on to the many little to-do's ...

New video: https://tk-pro.de/Pick-up/2022-02-21%20 ... 0shaft.mp4

My S-Class W222 was cheaper.

Life is like that. Enjoy it for the next 20 years and it is a bargain.

I like your point of view

Regards
Thomas

Driveshafts are a bit of a dark art. The input angle needs to be parallel with the output angle. Also the cheek of the cardan couplings need to be on the same plane.
This document by Spicer explains it all. I messed around with this with my Subaru Brumby, in which I put a 5-speed box.

Drive Shaft installation.pdf

[T-Modell]

Thanks guys for your help,

last night one of my daughters came by and we had the first "test drive" ... she took a video of the happy driver

https://vimeo.com/680296928

One of the things I've loved about this build is the insistence on making everything look period correct - you've even managed to set the timestamp on the camera to the correct era! Now that's attention to detail!

You made my day!

Regards
Thomas

[T-Modell]

And another one: https://vimeo.com/680316118

[Bartman4800]

Looks great, but I found the music a bit mellow. Would have expected "magic carpet ride" by Steppenwolf (American band with German singer)

[Christo C]

Is the slot in the top of the dashboard for a tissue box?

[T-Modell]

Looks great, but I found the music a bit mellow. Would have expected "magic carpet ride" by Steppenwolf (American band with German singer)

That song is actually on the MP3 card

Is the slot in the top of the dashboard for a tissue box?

You're wrong: That's for the tournament package of condoms; you cannot drive this car without an orgasm!

Regards
Thomas

[Christo C]

Is the slot in the top of the dashboard for a tissue box?

You're wrong: That's for the tournament package of condoms; you cannot drive this car without an orgasm!

Regards
Thomas

I’m certain the big ones I buy wouldn’t fit there.

[John Green]

MB used various thickness shims under the transmission mounts on some models. For example the W116's had a thicker one on the 6.9 variant. Many years ago we had one in with a tailshaft vibration and found that it was missing, replaced it and all was smooth.

trans mount shim.JPG

116 242 01 26.JPG

[T-Modell]

Is the slot in the top of the dashboard for a tissue box?

You're wrong: That's for the tournament package of condoms; you cannot drive this car without an orgasm!

Regards
Thomas

I’m certain the big ones I buy wouldn’t fit there.

@John: I cannot tell you how often this shim was in and out. If that would have solved the problem in any way shape or form, I had a custom one made already.
Thomas

[John Green]

@John: I cannot tell you how often this shim was in and out. If that would have solved the problem in any way shape or form, I had a custom one made already.
Thomas

As always one step ahead of me.

[T-Modell]

@John: I cannot tell you how often this shim was in and out. If that would have solved the problem in any way shape or form, I had a custom one made already.
Thomas

As always one step ahead of me.

Sorry, if that came across the wrong way. Mercedes here and me went through most pages of the EPC and WIS to find out alternatives / hints, also from other models.

Regarding this shim: It was out, since Tuesday it was in again (angle). However I fugged up the thread in the gearbox rubber bearing, so I had to replace it. Although the one installed was new in 2018, the new one was higher again. So we had to take the shim out again, as the gearbox was now too close to the tunnel

Regards
Thomas

[T-Modell]

Hi guys,

your opinion: after I had to take out the shim again due to the new rubber rear bearing of the gear box, I am just confused with all the noises and vibrations the car has. Remember, harder motor bearings, no motor dampers, no insulation on the fire wall ... Do you think the drive shaft is ok in these videos?

All videos are shortened now; first full acceleration is always in 2nd gear, the second acceleration always in 1st gear.

1. Video: rear drive shaft: https://tk-pro.de/Pick-up/2022-02-24%20 ... 20rear.mp4
2. Video: disc at gearbox: https://tk-pro.de/Pick-up/2022-02-24%20 ... r%20bo.mp4
3. Video: drive shaft front, gearbox: https://tk-pro.de/Pick-up/2022-02-24%20 ... %20box.mp4

Kind regards
Thomas

P. S.: I know, the videos aren't the best, but it's difficult in the driveway to attach the camera

[John Green]

is the top nut on the trans mount done up? The washer looks loose.

[T-Modell]

is the top nut on the trans mount done up? The washer looks loose.

Thanks John,
you were right, it wasn't tightened properly. I will take photographs of all screws and post them here ... as I am too stupid to fasten them

Just came back from a test drive ... lost one hubcap ... could see it in the rear view mirror. Called the local police, they referred me to the "Autobahnpolizei"; called them, I said "don't laugh", told them I lost it in a road works there and there ... the guy said "I will drive there personally and look for it" ... how good is that? Maybe he finds it ... ... I grew up (70s/80s) with the slogan "Die Polizei, Dein Freund und Helfer" (Police, your friend and helper) ... still true sometimes.

Kind regards
Thomas

[T-Modell]

Hi guys,
finally I can get to all the little to-do's to finish the cars. One "problem" was that the distance of the hand brake wire was very close to the rear axle. So I designed a little protection, 3D-printed from the same material as the fuel and brake line holders (flexifil). Installed it today, so the wire is protected!
Regards
Thomas

Design:

Installed:

[T-Modell]

....Just came back from a test drive ... lost one hubcap ... could see it in the rear view mirror. Called the local police, they referred me to the "Autobahnpolizei"; called them, I said "don't laugh", told them I lost it in a road works there and there ... the guy said "I will drive there personally and look for it" ... how good is that? Maybe he finds it ... ... I grew up (70s/80s) with the slogan "Die Polizei, Dein Freund und Helfer" (Police, your friend and helper) ... still true sometimes.

I got a call from the Autobahnpolizei ... they found it, got it and I can pick it up at their offices!
Thomas

[eddie]

Wow, I’ve not checked in for a little bit and look at all this good progress!! Love it Thomas, car sounds awesome seems to drive really well once the vibration was sorted and that interior is better than factory!

And you’ve got your hub cap back to boot. That’s all the good karma you’ve put out there coming right back around.

Fantastic, you must be very pleased with yourself.

Where’s the first big trip?

[CraigB]

I guess the advantage with the hubcap is you painted it a colour that makes it easy to find!

[pastelgrey300D]

Great news on the hubcap, maybe you need to put one of these stickers on the windscreen:

https://www.ebay.de/itm/133685144800?ha ... SwKSNdnGAh

https://www.ebay.de/itm/303627299643?ha ... SweJ1fE1~Z

polizei baden-wuerttemburg aufkleber.JPG

[T-Modell]

Haha,
that's a good idea ... just another update ... or one of the many things that went wrong:

The ABS was installed last year and after finding a fault with the overvoltage relais, it actually worked! However, the original cover of the hydraulic unit couldn't be installed anymore. I made a mistake when designing the holder for it; the body of the car doesn't leave enough space to place the cover of the unit. What to do?

You might have guessed it ... 3D-print ... I designed the cover myself and modified it in a way, that it could be put on top of the hydraulic unit. Additionally I used a slightly flexible material, which made it even easier. Sometimes I wonder, if that car could have been finished without 3D-printing ...

Regards
Thomas

[CraigB]

I need to get that cover off and on easily on my car - need to pull the ABS relays when using the car on dirt! I know there are not many dirt roads around anymore, but the ABS dramatically reduces your ability to stop on dirt. I remember the first time and you need to pull up in a 'garage' which is basically a series of traffic cones, before they then release you on the next timed section.... cones went everywhere as I sailed through them - adding about 2 car lengths to the braking distance acheivable without it! Makes me think about the thousands of km I did over the years up north in heavily loaded Nissan Patrols with ABS and the effect of that if you needed it. I didn't realise at the time and just thought it was all that weight.

[John Green]

I need to get that cover off and on easily on my car - need to pull the ABS relays when using the car on dirt! I know there are not many dirt roads around anymore, but the ABS dramatically reduces your ability to stop on dirt.

Good point, when Thomas takes it to the Deni Ute Muster he will have to remove those relays.

[tsharkey]

... when Thomas takes it to the Deni Ute Muster he will have to remove those relays ...

Surely there is an ABS disable switch in amongst Thomas switch banks ....

[T-Modell]

... when Thomas takes it to the Deni Ute Muster he will have to remove those relays ...

Surely there is an ABS disable switch in amongst Thomas switch banks ....

I actually forgot this, damn! But on a more serious note: my very fist Mercedes Benz safety training was around 1993; they used W201's and they installed an ABS switch-off switch, so you could experience braking with and without ABS on wet ground ...

Regards
Thomas

Edit: It was actually 1991, here's the certificate. My instructor was Christian Geistdörfer, a quite famous rallye pilot in the 80s ...

[T-Modell]

Hi guys,
tomorrow I have to do another round at Mercedes; the old motor struts have to go in again; the harder ones (R107 motorsport) bring the motor too high.

But I'd like to show you a little detail, that I only detected by accident ;-) ... something slid underneath the seat bench and I started looking for it. The amplifier of the music system as well as the wiring for the seat heating is there.

The carpet goes all the way through to the rear cabin wall - although you cannot see it. However, other people would have just somehow fiddled the cables in there. Here a proper, framed hole (two actually) were done by the saddler. I'm just fascinated about this work!

Regards
Thomas

[tsharkey]

Quality
Craftsman
Thoughtful

I'm sure the german for it is something like Thoughtfulqualitycrastman (Durchdachter Qualitätshandwerker)

[Honey500]

[/quote]

Think I like Thomas Stone guards better!

Fantastic workmanship as always Thomas.

[Nabstud]

So how is it all going Thomas? Hopefully you’ve been driving the pants off it making sure all the little bugs are ironed out…

[T-Modell]

Hi,
not a lot to report, as I'm working for a while now to lower the airfilter housing. Still scratching the motor hood. We either didn't notice in 2018 or whatever the reason is. At the moment I'm modifying a spare housing massively to lower it. Lot of design for the 3D-print ...

Regards
Thomas

P. S.: If I may be honest here ... and I don't know, if anyone understands: It probably still takes a lot of time for me to "trust" the car. So many things went wrong, I'm not an expert in building a car from scratch, so I'm really anxious driving it or driving further than 15kms away from home. Didn't have this with the SL f. i., I just trust that car. Everywhere I hear noises (existant or not), I'm overcautious and it still feels weird to me. Cannot explain it better, but that's how it is. Have I done too much? Is the V8 too much for the body? Are all the modifications technically ok or will something break? I know I sound weird, but ...

[CraigB]

Makes complete sense Thomas and I predict the trust will build over time. You brought back memories after I built my Amilcar, basically from a pile of parts. It has 'beaded edge' tyres that require high pressure to hold them and on wider sizes, a sleeve between the tyre and the tube to stop the movement of the beads pinching the tube. Eventually I worked out from international advice that I needed these super thick michelin tubes that stopped the pinching. Most people replaced them long ago with modern well based rims with modern tyres and I think that limited the local advice I was getting.

Long explanation, but the first time I drove it, I got up to 60 km/h and a front tyre went bang and completely came off the rim. Got some more advice, went driving and same thing happened. Kept going four times before I worked it out. But also just the noises and not knowing how it should be. Then there was a run with the vintage car club of about 1000km through the Flinders Ranges over a week, and I bit the bullet and just did it. Car went great and cured that fear to drive it. So I think it will come, but meanwhile it sounds very wise to keep using it within a limited distance from home.

But I think your engineering is all good based on features of the SL with same chassis characteristics and suspension.