| FAQ | Member List | Albums | Today's Posts | Search  |
| Welcome Guest. ( logon | register ) | |||||
| ||||||
|
| Topic Tools | Message Format |
| ||
| elevatorbernie Expert Date registered: Aug 2006 Location: Vancouver B.C. Canada Vehicle(s): 1989 280GE Posts: 1347  | RE: 300GD Kastenwagen, shouldn't do it, but... Good work Bram, that's going to be a great looking G when your done.  | |
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: 300GD Kastenwagen, shouldn't do it, but... Thanks guys for the compliments. Also some sheet-metal welding work is in front of me, but that will be taken off later. Now I'm working on the front axle. Fitted new Universal Joints both sides, new booths, used the hose-clamp method to tighten the steel bands, worked perfectly. Will source that tool for next time however, but for now it's all in place. Today used my 'Geteilter Ring' to fill out my shims on the axle housing king pin bearings. However in my M-B manual it says you should tighten those king pin bolts with 10Nm then measure the gap, on another manual you should get a big clamp on it, pressing those bearing together. Tried the clamp method today, but for reference willl try the bolt method tomorrow, see if they bring the same result. Already found today that on the underside king pin you got these dowels with can also alter the result if you don't pay attention. With some preload on it by the clamp, I've tapped the lower king pin with a plastic hammer and that already made a great difference how far the dowels went in. Anyway, will post some results soon. Furthermore I'm rebuilding the front calipers. Stripped them all the way, have them sandblasted and painted and got Perrot rebuild sets waiting for installation. Same for the rear pistons. At last lot of small parts are fitted. Part pictured is one worth looking at if you have trouble adjusting play in your throttle linkage. Mine was excessively worn with plastic bearing almost falling out the rubber housing, but it might be an issue on more older G's. (Pn = A 123 300 00 40 = HALTER ) Will post some details of other small fixes soon. Bram Edited by bram_r 11/30/2008 4:32 PM (DSCN7412k.JPG) Attachments ----------------  DSCN7412k.JPG (108KB - 3 downloads) | |
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: 300GD Kastenwagen, shouldn't do it, but... found my driver side door wasn't opening and closing smoothly. suspected the door hanger (?) first, but upon closer inspection I found a large shear in the sheet metal around the upper door hinge...see,s like it's been tampered with before as well...anyway, time to repair this section properly...repaired pics follow soon. Don't know how this happened btw, but we'll get it fixed. Bram Edited by bram_r 12/16/2008 5:56 PM (DSCN7426k.JPG) Attachments ---------------- DSCN7426k.JPG (95KB - 3 downloads) | |
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: 300GD Kastenwagen, shouldn't do it, but... Got my front calipers rebuild and in one piece again. Bought and made some new (M-B) brake lines on the front and rear axle. Almost ready to drive it out of my storage again and go to Vehicle-Inpection to have it registred. My front brake rebuild wasn't going as smoothly so far with wrong ordered seals and Perrot seals flopping off the caliper every time, but solved everything and ready to mount these rebuild and painted calipers. Just as I was starting to tighten the upper bolt (which I think is specified at 190-220Nm torque) the damn thread in the axle/hub housing stripped. This is M14x1,5 thread, I guess I have to buy a Helicoil set for this or find a company who can do this for me. Also very strange this thread stripped so easily, never saw this before, wasn't even close to my final torque and already it gave way  . Bram (Afb0202p.JPG) Attachments ---------------- Afb0202p.JPG (241KB - 3 downloads) | |
| ||
| ||
| Wout Veteran Date registered: Apr 2006 Location: Belgium Vehicle(s): Mercedes 280GE 1979/230G 1980/ C220CDI/A170CDI/ Posts: 145  | ||
| ||
| ||
| dentsmithy Elite Veteran Date registered: Sep 2007 Location: NFA Vehicle(s): 1986 230Ge, , 1979 240gd cabrio, AD-SL Posts: 912  | ||
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: 300GD Kastenwagen, shouldn't do it, but... crying out loud a bit too soon, since my own brother (!) had a M14x1,5 helicoil repair set in his thread repair assorti. sorry for the lousy cellphone pics again, but using some special tooling to have a nice and steady, square set-up, we placed the housing under a drill and drilled it to 14mm. Then using the same set-up, we cut using the helicoil tap (positioned in the drill) new thread in there and inserted the right helicoil insert. Should be good as new. Also freshened up the other thread (M16x1,5) and the threads of the left housing. Now back to reassembling everything again and adjusting wheel bearings and such. Luckily not too much delay after all. Bram Edited by bram_r 12/24/2008 12:19 PM (Afb0302.jpg) Attachments ---------------- Afb0302.jpg (231KB - 3 downloads) | |
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: 300GD Kastenwagen, shouldn't do it, but... I've done some more work on my Kastenwagen lately: - got it through inspection so I can take it to the streets. Drove my first 500 km in it, runs great for now. Passed my diesel soot / opacity test fairly easy, think engine is in good shape. - highway driving is not perfect, missing overdrive. Will install my 711.113 in the upcoming month I think. As long as I come across cracy prized om617a's, I'll be a happy camper with my om617 and 5sp. overdrive tranny. - installed new oil, fuel and diesel (pre)filters, done new fuel lines in engine compartment, installed new primer pump (old screw out pump as leaky as could be) - new engine oil, tranny oil and diff-oil. Ordered Redline stuff for the diff's and transfer case (found a dealer not too far from my place, nice to have this stuff in Europe as well). This will be put in at next service. - managed to pick up an used interior from an ex-german police (Polizei) G. Dash is padded, got lockable compartments in the doors, a rifle compartment in the headliner, and all switches and stuff in great shape. Head liner is white, doors are grey. Will post pics soon. - did a lot of small repairs, installed new front-indicators, lot of new small parts thanks to the EPC  - already found out my floorboard where a bit wet after rainy weather, so when stripping the old and worn interior last weekend, I took the opportunity to first do some rust repairs on the front of the cab / firewall. Everything worked out nice, nice welds. Did some seam-sealing tonight, now ready for primer. Repaint and/or full body-off repair will follow maybe next winter, then all paint will be stripped again and G will get a new color. I do like the original M-B light green olive-drab colour, but I also like the '70-ties' orange G in this ad http://calgary.kijiji.ca/c-cars-vehicles-SUVs-trucks-vans-1984-Merc... very nice. Anyway it must be a 'flat' colour, no metallics or something fancy. Plenty of time to do some looking around for other examples... Anyway, two pics to show some work in progress: - removed interior and front (inner) fender to do my rust repairs on firewall. - as can be seen, original color was colorado beige (1470) but was repainted white. Bram (DSCN7555k.JPG) (DSCN7543k.JPG) Attachments ---------------- DSCN7555k.JPG (93KB - 3 downloads) DSCN7543k.JPG (111KB - 3 downloads) | |
| ||
| ||
| Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3005  | ||
| ||
| ||
| Inkblotz Expert Date registered: Apr 2006 Location: Georgia Vehicle(s): 90 300GD "Thundering Turtle II", w/ 603A turbo Posts: 3186 | ||
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: 300GD Kastenwagen, shouldn't do it, but... Inkblotz - 4/2/2009 3:55 AM Bram would really like to see your solution on how you repaired that door hinge area. Mark Hi Mark, for now I grinded the 'crack' a bit blank and welded it. It's solid now, but the upper door hinge area needs more work later. I will show pics later to show how and why this crack occured. For now some more pics of my repaired firewall. On the corner sections multiple layers of steel are spot welded together and pose a rust problem on plenty G's I've seen. When you got wet floorboards after some rain, check the corners of your footwell area, and check for rust spots. When you remove inner and outer fender you get good acces for grinding and welding. After welding I used some sealant to copy the seams that MB made once, after that I put some primer over it. After welding I mounted my 'new' dash. No pics yet, but found an EPC pic. Apparently the glove-box is sacrificed for some 'Funkgerate', radio equipment. Anyway, dash is padded and got some extra switches, certainly better than that used and abused set I got with the car. Then replaced my engine mounts. It is possible to replace these with the engine in place. Especially the driver side mount was torn all the way through. I put donut mounts A 4602420813 and A 4602421013 back in place. Last picked up my BF-Goodrich 255/85/R16 tires tonight. Good a real good deal on them, but these tires certainly are large! Next week I will have them put on a set powdercoated G rims (6"). The rims that are now on the G I may have widened to 7.5 or 8" according to Loki's advice. Widening is quite cheap I found out, but plenty of time to sort all my gearing, springs and shocks out. For now I still got a lot of small fixes to do and get going on my 5 sp. tranny swap. Bram (DSCN7575k.JPG) (DSCN7577k.JPG) (dash_BGS.jpg) (DSCN7601k.JPG) Attachments ---------------- DSCN7575k.JPG (65KB - 3 downloads) DSCN7577k.JPG (69KB - 3 downloads) dash_BGS.jpg (63KB - 3 downloads) DSCN7601k.JPG (55KB - 3 downloads) | |
| ||
| ||
hipine Date registered: Jul 2006 Location: US, CO, Bailey Vehicle(s): 460 1980 280GE w. 617A  | RE: 300GD Kastenwagen, shouldn't do it, but... Great work Bram! And thanks so much for taking the time to post so we can follow along in the fun! Speaking of colors to paint it, I see that it was originally the tan color. I've always liked that color too. Maybe it's a crime, but I have to admit I still love the "Pastel Green" color of my old Land Rover Series 2A and have thought about what a G would look like in that color. Have a look at the color of the surface that all the stuff is sitting on in the first picture in this article. That's the bonnet of my old Land Rover. I still love that color. My G has a tan headliner and black/tan interior, so I could probably get away with painting it this color. With a white roof, and body colored wheels....hmmm. Of course all my Land Rover driving friends would give me grief about being a Land Rover wanna-be. But I might be able to live with that to have a Pastel Green G. Thanks again! -Dave G. | |
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: 300GD Kastenwagen, shouldn't do it, but... in the meantime between upgrades and repairs some work to be done with the G as well. last weekend, towing 8 meter trailer with some steel construction beams and some wood. Total weight about 2750 kg's approx. G did a great job, only loosing some speed on some longer grades, but still a comfortable ride. (g-a1.jpg) Attachments ---------------- g-a1.jpg (41KB - 3 downloads) | |
| ||
| ||
| Initium Veteran Date registered: Dec 2007 Location: Oslo, Norway Vehicle(s): 300 GD LWB Posts: 195 | RE: 300GD Kastenwagen, shouldn't do it, but... bram_r - 5/11/2009 2:31 PM G did a great job, only loosing some speed on some longer grades, but still a comfortable ride.
Sorry Bram; dont believe you. In the Netherlands you dont have anything other than FLAT terrain. A bit oposite to Norway, where the G`s REALLY have to work hard...
:)
Initium | |
| ||
| ||
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: 300GD Kastenwagen, shouldn't do it, but... Initium - 5/15/2009 9:23 PM bram_r - 5/11/2009 2:31 PM G did a great job, only loosing some speed on some longer grades, but still a comfortable ride.
Sorry Bram; dont believe you. In the Netherlands you dont have anything other than FLAT terrain. A bit oposite to Norway, where the G`s REALLY have to work hard Initium ha, you're absolutely right of course, no serieus uphill driving here, but on the stretches that are a bit uphill here in the east of the country around Arnhem, I lost some speed from 80 to 60 km/hr. Taking the Norwegian route would be a whole other story ! snyder.hunter - 5/15/2009 9:29 PM Updates? Let's see some pictures! Upgrades huh, well, no major upgrades, but still some: - installed my ex-police padded dash and some new switches, lot of harness repairs at the same time - bought and installed my Isringhausen spring-suspension seats - new linkages on my accelerator mechanism, the old ones were quite worn, came off a few times while driving... - fixed odometer, counts the kilometers again - fixed all dash and indicator lights - fixed a lot of bad grounds on the rear, all lights and trailer socket connectors are ok now - will have my old set steel 16" rims widened to 7.5" for the 255/85 R16 tires by the end of next week, bought another Cooper Discoverer S/T set for more on-road comfort - bought 'new' set of inner fenders, old ones were too rusted, waste of time to have them fixed - installed my military style fuel filler, it sticks out a bit, but this is cause it has a coarse filter in the filler, nice. I might have to modify my spare tire carrier now a bit, but that wouldn't be a problem - almost bought my 617a engine, but having a hard time contacting the seller. Would be nice to do my 617a swap together with the 711.113 installation. some pics of the fuel filler, see below. Don't mind the rust holes, my MB repair sections are waiting to be welded in Bram Edited by bram_r 5/15/2009 8:10 PM (ff1.jpg) (ff2.jpg) (ff3.jpg) Attachments ---------------- ff1.jpg (46KB - 3 downloads) ff2.jpg (42KB - 3 downloads) ff3.jpg (60KB - 3 downloads) | |
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: 300GD Kastenwagen, shouldn't do it, but... here some pics of my widened steel rims, 7,5" wide now, widened on the outside with 1.5" has cost me E 25,- per rim. next step is to sandblast and powdercoat them and have my 255/85 Cooper Discoverer tires put on them. Bram Edited by bram_r 6/14/2009 5:37 AM (DSCN7848k.JPG) (DSCN7850k.JPG) Attachments ---------------- DSCN7848k.JPG (104KB - 5 downloads) DSCN7850k.JPG (109KB - 4 downloads) | |
| ||
| ||
| hipine Date registered: Jul 2006 Location: US, CO, Bailey Vehicle(s): 460 1980 280GE w. 617A | ||
| ||
| ||
| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | ||
| ||
| ||
| Fernando BR Date registered: Jan 2007 Location: Brasil Vehicle(s): G500/05 300GE/91 300GD/80 | ||
| ||
|
