Cargo floor panels cont'd ...

3 September 2020

Still a lot of effort and hours on the body works. Here's some examples of the cargo floor panels. It wasn't just having the profiles done ... it has to fit the cargo area and the ends should look like original. Imho great work and I'm looking forward to the finished panels.

Hours just for the license plate holder ...

22 August 2020

Here's just another example why all this is complicated and takes a lot of hours. The license plate holder on the cargo door should be rebuilt properly as it is one key element of the design. However it is in bad condition (no surprise) and not that easy to rebuild. When the cargo door is closed it should be fixed upright and when you open the cargo door it should fold down, so it can be seen too.

The mechanism is totally rusted and fucked up. There's a spring bolt, that fixes the license plate holder in those two positions ... Timo will rebuild it to the original ... estimated hours: 15 (!).

Taking shape ...

29 July 2020

Lots and lots of details have been done so far ... it's just difficult to see all those details. But as the rear fender reinforcement is now properly in place, Timo continued with the outside of the rear doors ... still held by magnets, but you get the picture. Can't wait to have the car back ;-)

Another "proof" for an original car ...

23 July 2020

Timo sent me two pics today from "hand-restored" original cargo door hinges from the Argentine Pick-Up ... even those elements were produced locally. Absolutely amazing ... another "original part that could be saved.

B-pillar / Rear doors ...

19 July 2020

Timo continues on the b-pillar and the rear doors. As the original pick-up sheets were so bad, we use the rear door sheets. Of course additional sheets have to be handmade to fill the gaps. Also the bottom of the b-pillar is a challenge (original too rotten again), so more sheets have to be made. At the moment the estimate is > 200 sheets to be made.

Cargo area cont'd ...

12 July 2020

To give you another impression of the massive amount of work that has to be done: The original reinforcements in the rear fenders were so rotten and bent, that they had to be redone. Of course not straight, but it has to follow the car's shape. To quote Timo (to me that's magic):

"This is done to bent the profile the correct way. The profile should be following the sideline of the car, which is straight till rear wheels then it bents inward quite strongly. After changing few bits (one meter) of the profile it was too straight. So welding a dot will shrink the surrounding metal some tenths of a millimeter... so this is the way to bent the beam controlled way. If you check it closely the dots are mainly on the inside of the profile also the amount is changing along it."

Cargo area / Cargo door ...

2 July 2020

I guess we're now > 130 single metal sheets made from scratch by hand. The cargo door will be - more or less - rebuilt completely new too, see the pics. It's just put up there for design purposes. Timo is putting a huge effort into this, nobody - I guess including him - would have imagined the amount of work for this transition.

Bild in Lightbox öffnen (open image in lightbox). Just one example of a hand-made sheet ...
Bild in Lightbox öffnen (open image in lightbox). Looks like a car with temporarily fixed cargo door ...

Cargo area takes shape ...

12 June 2020

Timo is working hard on rebuilding the cargo area and it is taking shape! Those fantastic cargo floor panels, especially manufactured from a local company, are cut to size now. They're not fixed or finished, but it gives me a really good picture of how it will look like. Thanks again to Timo for this fantastic work!

Cargo area cont'd ...

More and more panels are finished by Timo, the rear end is taking shape. Quote Timo:

Just made some calculations. 😊
- over 100 pcs small and large made from steel sheet and tube.
- 10 new/used MB parts, most of them had to fixed some way
- I guess some 30-50 pcs parts be made... 

No words to be added ...

2 June 2020

Parts self-made ...

In case anyone still wonders why this project takes time, here some more reasons. Many many parts have to be redone from scratch as the Pick-Up parts are useless. In the last 30 days roughly 150 hours went into that. I think this is fantastic work from Timo and it will make this Pick-Up a high-end car!

Cargo area cont'd ...

It turned out to be pretty time-consuming, this cargo area. Lots and lots of smaller pieces that have to be fit perfectly as they will be visible later. Unfortunately many parts of the pick-up are so rotten, that they have to be "re-invented" ... Timo is doing a great job, but - understandingly - takes longer than expected (which is THE ONE constant all over this project!)

Cargo floor panels manufactured ...

As I tried to get those floor panels manufactured in Germany, I was so shocked about the price quoted. So the original plan was to ask my furniture maker to produce a nice wooden floor for the pick-up. However that would be a great deviation of "original".

But Timo did another great effort: he found a company, that could produce the raw profile panels for the cargo floor ... even at a reasonable price. So this part will also be original ... no need to mention, that the original pick-up panels were rotten too. Thanks for that!

8 May 2020

Bild in Lightbox öffnen (open image in lightbox). Original and newly manufactured ...

Rear cabin wall completed ...

The gap between the rear cabin wall and the car's floor is now "filled up" ... again really nice craftmanship ...

23 April 2020

Cargo area cont'd ...

Timo was "productive" over Easter, things take shape. Still only spot-welded, but it is a fantastic progress. He wrote to me, that he used 50 flexi discs, one bottle of welding gas and quite many meters steel profile and sheet metal …

13 April 2020

Rear Cabin Wall in place ...

9 April 2020

The rear cabin wall is in place now, not welded yet but it looks good. The gap to the doors is perfect and the long, detailed work of Timo pays off now. Or to quote him: "It's like eating an elephant, bit by bit" ;-)

Rear Cabin Wall extended ...

27 March 2020

Timo continued his great work with the rear cabin wall. As the bottom 30cms were completely rotten, he made a perfect sheet of metal himself. Fits perfectly and looks great!

Roof's off and "parts rescue" ...

19 March 2020

Timo could save some original parts from the Pick-Up and had them sandblasted. They were in a reasonble condition, so they can be used.

The roof's off now, the car didn't fall into pieces ;-) … so works can continue! Again, but it cannot be mentioned often enough, a great job and I'm very happy, that Timo does it so thoroughly!

Pick-Up slowly takes shape ...

13 March 2020

Director's Cut (to quote Timo) ;-)

Again fantastic progress from Timo: The Pick-Up (ute) takes shape! Not welded yet, but the roof is taken off, rear passenger wall fits in … just enjoy the pics!

Cargo area continued ...

11 March 2020

Again more progress on the body works front: The cargo area support takes shape, it looks fantastic and the quality is definitely better than original.

Cargo area reinforcement ...

4 March 2020

Progress, progress progress! As part of the cargo support structure, Timo designed that great looking part on the photo. Hidden inside will be a 30x50 mm² profile (3mms thick), which will be welded between the shocks. That will increase the body stability enormously … or to quote Timo: "With a pair of extra horses some additional reinforcements could be needed" ;-)

Bild in Lightbox öffnen (open image in lightbox). Massive reinforcement in place ...

Cargo area support cont'd ...

2 March 2020

This is the advertising section for the fantastic work of Timo ;-) :

He continued with the cargo area support. Those profiles are self-made, must stronger than the original … and look at the detail, how they are connected. I guess it's finally time to call the body works of this Pick-Up better than original!

Repairing the rust bucket cont'd ...

22 February 2020

So Timo is still busy repairing the rusty parts of the sedan. Before the (ex-) rear bench, there were some tricky spots to be repaired. As you can see on the photos, he's done a perfect job, also putting the nuts in the correct place again.

The trunk floor was rusty, we knew that. As this will be hidden in the future due to the cargo area, this can be fixed in a more easier way. I could source the rear cross-bar in Holland, so at least that can be used as a reference.

Pick-Up parts back from sandblasting ...

24 January 2020

The Pick-Up parts came back from sandblasting. Not too good as we expected, but doable. After a chat with Timo it turned out that the back of the passenger wall and the cargo door are more tricky than it looks. Lots and lots of dents and there must have been severe damage to the rear end. Lots and lots of tin used, many many little sheets of metal for repair ... and so on and so forth. Why should it ever get easier? :banghead:

Well I'm SOOO lucky to have someone like Timo who takes on such a job. With all the setbacks so far, it feels like the lottery win with him. :rockon:

Sedan back from sandblasting ...

The sedan body went to sandblasting. A few more small holes, but all in all not too bad. That the trunk floor was rubbish, we knew. So the rebuild can start from there.

This week the pick-up parts will come back from sandblasting … let's see what's left ;-)

19 January 2020

Starting on the rear end ...

10 January 2020

Body works continue … the trunk floor of the sedan is rusty, we knew that. So the bottom of it will be rebuilt from scratch. As the cargo door is very pickup-specific, we will use it. Also the bumper of the Pick-up is much lower than the one from the sedan.

The rusty rear cross bar I could source as NOS, but the green wire will be replaced with an orange one ;-)))

Bild in Lightbox öffnen (open image in lightbox). Professionally attached Cargo flap ;-)

Fixing rust on the floor ...

12 December 2019

Although the sedan is pretty good regarding rust, some holes were there and Timo starting fixing them. He even made a special tool to get the shape right. So here's some pics of the floor behind the seats using original metal from the pickup's roof.

Modifying the sedan: tunnel ...

7 December 2019

 

The sedan's front (donor car) is now nearly finished; all obsolete holes are closed, the left fender is modified and the battery rust issues are done.

Due to the V8-gearbox the W115 tunnel had to be extended. As a hint for Timo we welded in two bars, so he knows how far the extension has to go. Also the shape is very important as the "new" centre console has to properly fit on top.

Start of rebuilding: Cargo Area support ...

15 October 2019

 

Unfortunately the whole support construction of the cargo area is completely rotted away. So this will be rebuilt from scratch, but exactly as it has been.

However, Timo found out, that some parts of the Binz construction is not really up to standard, so some reinforcements will be included, so the whole body is much more stable.

It is planned to put this subframe into the sedan first, so it will stabilise the whole body before anything is cut off.