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1954 Mercedes Benz M189 Engine repairs


Some time ago I rebuilt this engine but during the running in process it had a rattle, which would only come at a particular rev range ,but was otherwise smooth. Once the sump was off ,the bottom of the oil pan was inspected and odd tiny peices of metal which looked like bearing metal . The rod caps were removed and the bearing,although not completely destroyed are scuffed really badly.  Why? 


My initial thoughts were to pull the oil pump off as this is an obvious oil supply problem .Although the pump was inspected atc when the engine was rebuilt I decided to strip it right down and two things popped right out . First, the round wear mark in the pump shaft housing . and that square hole . It’s actually a fault in the pump housing as far as i can figure .It would appear that this hole has allowed the oil ,once hot to lose a fair amount of the pump vacuum as it sucks the oil up from the sump . So,once the car got up to temperature and at highway speeds the oil volume would fall away although the gauge would still be indicating full pressure at engine speeds above idle speed. 

Next step will be to replace the oil pump and bearings and inspect the oil pressure relief valve ,then reassemble the engine and install it back into the car.


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220SE Restoration .


This is an early 220SE which has been sent in from overseas for a complete make over. .All of the bright trim is being removed followed by a strip back to bare metal .IMG_0072

Unfortunately some repairs in the past were not very well done and will need to be made right to remove rust which is just starting under the body filler.

Here, the front mudguards have been welded to the sill/rocker sections. These are unibody car and they flex a lot which cracks any joins which should not be welded up.


Not a very clear picture but this is the Drivers side.


This the rear end of the Sill section at the drivers side rear door. The seams have been filled,again this must be rectified.


Passenger is side is the same with much work required to fix. As can be seen in both pictures, both jacking points are missing … 😦


This the Seam at the top of the rear quarter which again has been badly filled and is cracking with rust showing through the paint .


The bottoms of the doors are showing signs of rust where the door rubbers seat , this will have to cleaned out and treated to prevent further rust.


Inside the door groove there is a little rust which has just been caught in turn.


In the past the doors have been sprayed inside  with bituminous under coat, which unfortunately never works .This will be removed and a proper rust sealer applied.


This is the drivers side 1/4 light frame which unfortunately is rusted away so the hunt begins for a new or better one.




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Mercedes Benz 280SE 3.5 ute Engine swap.

The new engine and trans are installed with a new oil pan ,rear and front crank seals. New injectors with new intake manifold gaskets,timing chain and rails should see a nice reliable tow car for the owner 🙂 .New fuel hoses and clamps will connect the fuel system together .

450SLC repairing rusted out sections and severe panel damage from previous repair.

The battery has been leaking onto the passenger side (Left) inner fender and rusted out the floor. In this picture the rusty part of the footwell,next to the firewall has been removed.

This is the peice from a donor wreck used to replace the rusted part. As can be seen all of this has to be inserted to replaced the parts damaged by leaking battery acid.

This is the part that was removed, as can be seen it involved a lot of work with much panel damage covered up by previous repairers .

With the rusted part removed including the sill and jack point the damage doesn’t look so bad.

The replacement section in Place

The Circle illustrates a gap,this was where a peice madein the same shape as the Sill Section but 1.5 mm smaller has been placed inside ,then used to weld the two parts together and add strength.

So the next part is to replace the right rear quarter . this had been “repaired” in the past but wasn’t the correct shape and was full of body filler . The spot welds have been drilled out ,’unpicked’ . The center peice below the rear screen has to be removed to fix rust,but that comes later.

In this shot, the arrow points to a wrinkle in the B pillar where it’s been bent in the past in an accident . The outer skin has now been removed making this repair easier.

This is the right hand wheel house

The wheel house has damamge which has to be straightened before the new skin can be fitted .

In this picture,it shows how the old skin was startng to rust on the inside because the window trim was leaking. Below, the area is indicated by the orange arrow .the yellow arrow indicates where holes were punched into the panel In the past, in an attempt to pull a dent out . this did more damage ,requiring the replacement of this part.

The wheel house has lots of dents made when the previous attempt at repair was made.

1974 Mercedes C107 rebuild.

A customer has engaged us to rebuild his 1974 450SLC. This car has been rebuilt and maintained throughout it’s life including some time off the road in Storage. the paint is tired and flaking off so it will stripped back to bare metal,rust repaired and repainted before reassembly. it’s also rather special in that it will be four speed manual.

The car has been stripped to the bare shell in preparation for Stripping to bare steel .

The shell is very dusty after being in another shop for two weeks.

This is the right hand corner of the body, the body has little rust compared with others i have done over the years. that is a hole in the centre.
Top right corner of the cowl reveals more holes,but this is the result of bad repair work in the past It is how water got into the cowl made the rust hole at the bottom.
Another close uip of the right hand corner.
Manual Flywheel for the 450SLC, plus clutch. it is a used item but in very good condition.
it came from this engine, a M116 3.5 Djet engine which has had some work in the past and despite appearances, actually runs…and is for sale.
Both Cylinder heads are stamped with a rebuilders mark and have over heat tell tale plugs fitted.
Clutch and four speed trans as removed from the Donor car.
Damper on the 450 Engine covered in residue from a leaking water pump.
Suspected leaking head gaskets ,probably over heated because of the faulty water pump.
More external oil leaks
Engine is up side down in the engine stand ,oil leaking from rear of head.
Oil seepage from left hand head.

Mercedes Benz 300 SEL 6.3 repairs part 2


This is the Sump for the 6.3 M100 Engine .On the right front corner. Oil was leaking through the weld and the side of the pan was full of cracks. All were leaking.


The welds were very porous and leaking badly.


The easiest way to fix all of the cracks and bad welding was to cut the bottom off and make a whole new bottom and weld it in place.



The Engine was rolled over to get the Sump off and to replace the crank seals . The crank shaft had to come out ,but bearing damage was revealed.


Number 7 Conrod bearing was flogged out and the conrod bore distorted . The Big end bore was resized.


Careful measuring of the crank revealed it to be free of any damage  so will be cleaned and reinstalled.


The Bores are ok and only needed a light hone to restore the crosshatch pattern. The rings are worn and will be replaced.

to be continued….

Mercedes 220SE Restoration. August 2019 update!!


The final coats of paint are on and just need polishing now.



Moved out of the paint booth and taken off the Rotisserie .The shell is now on the hoist to receive all the under pinnings


The 6.3 is now headed into the booth to be finished .Here,it’s on the chassis rack which is on wheels


The Engine bay needed a bit of touch up so here it’s masked up so the paint overspray can’t escape


The finish is Satin Black but here it’s still wet so it looks glossy. This type of paint takes a few days to set properly.


Here is the trans tunnel and I’ve been refitting the fuel and brake lines. All of the clips have new rubbers and the plating restored.


The steering column is in place ,along with the front part of the wiring loom ,Horns and brake lines. The pad on the firewall has been replaced with a new one .All Australian Built Mercedes Car had a black Engine bay.


The cable here is the new generator cable ,with the Cold start Valve ,which is different to all of the later model 220SE’s which have the cold start valve in the intake manifold .

In the lower left of the picture is the aircleaner which has been restored . The brake reservoir has had the bracket restored


The cables,the cold start and flasher relays,ignition coil new brake lines are in place. The injection pump cold start wiring are in place .The Heater feed pipe is in place ,after being remade in copper to prevent it rusting out again . The little plaque on the left inner fender is the Body tag from the Australian Mercedes Assembly plant in Melbourne with it’s Australian only body number.


The Front and rear ends are nearing readiness for installation .


Here is the engine as removed from the Car initially .It needs a lot of oil leaks rectified and the valve stem seals replaced. I did a leak down test and it has good sealing and compression’s on all six cylinders.


a couple of days later and the crank seals have been replaced, The Damper had to be replaced because someone in the past had fitted it in the wrong place(the damaged one is sitting on the frame under the engine. .I have no idea of how they managed to set the ignition timing . The large black bracket is for the air conditioning compressor. All of the hoses have been replaced . There is a new water pump air bleed pipe ,and all of the mounting bolt holes needed to be repaired with helicoils.

All of the exhaust valve oil seals had been fitted incorrectly ,so they leaked badly.

Both intake and exhaust seals were replaced on all cylinders.

The timing chain is worn out as is the tensioner so those will have to be replacedto get the engine performing properly.


This is the inside of the Thermostat housing and as can be seen ,the seat for the bottom part of the thermostat itself has been eaten away over time so it wouldn’t have been working properly. This is very important with the mechanical fuel injection system which relies on the coolant circulating to the injection pump to set the cold and warm running mixtures.


Here, the corroded one on the left is compared with a good part.

Next… reassembling the engine trans together and fitting to the front in preparation for fitting into the car.

Mercedes 300SEL 6.3engine stand

I needed a very heavy duty engine stand to support the Engine from the 6.3 project.

I had a heavy engine stand but it wouldn’t hold an M100 Engine ,so the plan was to use the end of a W112 rear axle with it’s heavy bearing and flange .


Normally I’d say this was rare part (very few W112 cars were made)

A length of the axle housing was cut off in the lathe.


The actual axle shaft was then measured to length (250mm) a section of the axle taper was machined flat,so the shaft was parrallel ,then parted off in the lathe.


parted off axle stub Seen here sitting on a base originally from a ute crane (crane on the back of a pickup truck ) These were welded together so I have a face plate to mount the engine.


The axle housing stub was then welded to the engine stand to provide a rotating point.


I then made a Fork,which supports the weight of the engine at the mount arms ,the bell housing end bolts to the two brackets to support the rear of the engine.


Here is the engine ,upside down ,in preparation to repair the cracked sump and leaking rear main seal.


Eventualy i will add a reduction gear to the shaft at the rear so the engines can be rotated. They roll easily enough on the stand but there is nowhere to lock it in place yet.


Mercedes 220SE restoration ,paint work continues

IMG_0242The lour coat has gone on ,4 coats followed by 3 coats of clear.  This will now be flatted back after a weeks curing. The car will then be flow coated ,then polished.


This the first lot of clear coat which has to be flatted ,Sanded smooth then recoated to bring up the gloss and add depth to the Finish .


Mercedes Benz 300 SEL 6.3 repairs

This is part of a 6.3 rebuild which began as a simple gear box swap,but while working underneath the car i noticed a lot of damage and some really badly repaired accident damage .Apart from rust in the usual places the front cross member was rusted out and the car was 50mm shorter on the left side.This pic shows the state of the left hand side bumper support cross members . Not only bent it was rusted through . To repair it in the past,someone had simply welded a patch over the top of the worst dent and welded the bumper bracket to that.





Here is the Left hand upper part of the fender to radiator support panel. It wasn’t welded together as it should have been. 



The entire front section had to be replaced. The rust in the bottom of the center section can be seen here . The panel was distorted completely out of shape .



The engine has to be removed to gain access to further damage hidden under the firewall and to check the chassis integrity. 



The circle indicates the bend in the left hand chassis rail . The front end of the rail was bent down 25mm .Above it there are creases which had to be worked out. 



This is the upper part of the inner fender panel ,which was bent back.


The inner side of the rail was heated carefully and force applied to bend the leg back up again.


The outer part came straight with a lot of work.


I used a laser to make sure the both sides were even .


With the front parts removed ,the damage to the chassis extension can be seen clearly .The left hand extension piece(arrow)  was actually bent to the left .Both pieces needed to bent straight. 


The Right hand side was OK,not requiring any work. 


The next step was to repair the damaged inner fender and weld up parts where it was torn from the radiator support panel .


As the panels are straightened out it was important to constantly check the chassis was still within specs.


This the left hand outer part of the footwell . It has been pulled back into shape as it was pushed back contributing to the shorter measurement on the left side.


The new parts are shown here temporarily clamped into place to ensure the car is coming back to shape.


Almost there!.


After a few hours work straightening.


I use a trammel to measure from a set position under the chassis where there is a hole which takes one end,this is the other where a set measurement shows the crossmember here is correctly placed.


The yellow arrow points to the trammel rod and the red arrow shows the needle end in the chassis measurement aperture.


The Yellow arrow here points to the laser line where i am making sure the crossmember is fitting level .


As soon as i am 100% sure the crossmember is sitting in the correct place etc,I weld the rear part to the chassis extensions.




The radiator Support panel is now lined up and checked with the laser before clamping and welded into place.


The trans tunnel was very badly damaged in the past,probably from a frontal impact,and was 50mm shorter than it should have been.


in this picture the tell tale ripples in the trans tunnel . The engine had been pushed back in an accident in the past ,leaving the impression of two bell housing bolt heads in the firewall . 


The hole in the tunnel on the right of this picture is the access for the starter motor bolts. There is little room in a 6.3 engine bay. 

Inside the car ,various parts were damaged ,such as the heater case and this,the dash board brace where the bolts have been sheared off.



The firewall wasn’t only pushed back,but the welds for the tunnel have been torn away.


The inner fender to firewall end has rusted and where the parts were repalced in the distant past,they weren’t welded but simply brazed together.


I removed the tunnel So I could straighten it out and pull the firewall back out again .



In the past someone had used heat to try and removed dents in the tunnel,where the black burn marks are.



The other interesting this was the method used to hold the gear shift in place.

IMG_0099 (1)


The lever was stuck in place with Sika flex.







The sika flex was stripped off  and the tunnel put back into shape the shifter base was also bent so that was repaired .



The side flanges where the car is spot welded to the car were replaced as was the front end where it is fuse welded to the firewall aperture .IMG_0158


Under the car,the cross member on the tunnel was bent,so that has been straightened also .


In the spray booth.


This the firewall on the passenger side (Right hand Drive) .The side panel was replaced in the past and Brazed into place. Rust has taken hold so this whole piece has to be removed and replaced.


There is rust in the Sill /Rocker section at the front to be repaired.


Front end of the right hand sill/rocker section.


The hole in the upper edge of this picture is from rust forming behind the jack point on the right hand side.


The mess revealed under the coats of bituminous underseal.


I cut the outer skin off and as can be seen it’s was pretty rough inside.


Cleaned up in preparation for new steel to welded into it.


With the new peice welded in place, a spare guard is bolted in place to check fit .

Next: welding the tunnel into place and repairing the remainder of the rust .

220SE Restoration Update.

Lots of work has gone into Priming the body. After the first 3 coats of primer to reveal any dents etc ,the bosywork was gone over again to remove the dents as much as humanly possible. This was followed by a coat of polyester to smooth the surface. This took 3 weeks of concentrated sanding to get smooth with most of it actually being removed in the process. Next step was the first layer of actual primer,a 2K high solid,high build primer. This is the polyester coat.D loh5


This is the first layer of primer with spots of glazing putty,these are  where low spots have been filled then sanded down  . The light helps high light flaws ,invisible normally.



next step is to apply PVC coating to  replicate the original undercoating .IMG_0187


The sills are coated .This is the right hand rear wheel house .

IMG_0188 (1)

This the right hand rear boot box. These panels are all new and again the finish is done to replicate the original rough textured look.



The boot area was stripped to bare metal to remove layers of old paint and bitumin underseal . Here it is 2K primer with PVC to help deaden Drumming



outside the boot is masked to prevent overspray from the boot paint landing on the primer.


Boot finished in the correct satin black ,as can be seen it absorbs light….All seams on the new rear panels are seam sealed to prevent moisture getting into the joins and causing rust.



Next step is to paint the door jambs and openings with the final base color .



The insides of the doors have been coated to reduce noise and prevent rust.


The final layer of primer has been applied and guide coat applied to reveal the last of any flaws that might not be visible until now. the boot and engine compartment are masked off here.


Sanding has begun ,after 8 hours constant work,only the right side was finished…


Mercedes 220SE Restoration: Final bodywork stages.

After much body work to get the shell straight and true as possible ,the doors etc have been bolted on and adjusted .


D loh5D loh6D loh 4D loh 3

Guide Coat is applied before block sanding begins.

D loh

Right front mudgaurd has been block sanded .the dark blotches are low spots which have to be beaten back up again .

Finally after much panel work the long process to paint the body has become .

The bare steel has been treated with a deoxidiser and given the first coats of primer surfacer.