Spare Parts (IV): 2-pole Cable Connector ...

3 March 2020


There's quite a few of those 2/3/4-pole cable connectors used in a Merc, e. g. in the doors for the electric windows. Most of them are broken, but beside the "optics" it could also be an electrical problem, if they are not 100%.

They aren't available at Mercedes anymore, but as a reproduction. The last time I looked them up, one was around 35 (!) Euros. Too much for me. So I started designing them in my own way. I used two M4 nuts, which are pressed into the plastic. Then a little cover plate is screwed on the bottom.

Not as sturdy as the originals, but good enough for me!

Spare Parts (III): Gasket Wiper Motor ...

1 March 2020


"As usual" I had two windscreen wiper motors; the one from the pickup didn't work, the one from the sedan did. I had to get rid of the intervall electronics attached to the motor, as the R107 had a relais for that already, which I included in the harness.

However, both gaskets were 40 years old and done. They're not available anymore, so I thought I do them myself. Having already experimented a bit for the rear light gaskets, I found a 2k silicone which met my requirements. I am mixing two of different shore hardness and add black colour to it.

I designed the gasket itself in 3D and then used a cylindre to "substract" the gasket from the cylindre, i. e. I had the "negative" form.

The design of the gasket is simplified, as in those days they tried to save material. It fits in the frame and hopefully prevents water from getting inside the car.

Spare Parts (II): Rubber blocks ...

10 February 2020


Another stuff I experimented with are the rubber blocks, that are used for brake lines and fuel lines. Some aren't available any more and - due to the conversion - I needed some "special ones".

I designed them and after a lot of experimenting I fould a flexible filament, that is very very close to the original rubber consistency. It is a bit stiffer than original, but the lines get in.

Tipps for the 3D-print:
1. The filament is from FormFutura and is called Flexifil (ABS)
2. Flexifil does not stick to the printing bed (I tried a lot ;-) … so I constructed a "holding plate" around the rubber parts to hold them in place. Therefore you need a dual extruder Printer, black ABS in the one and Flexifil in the other one.

The print went for 23 hours and it turned out good … so just breaking off the plastic plates around the rubber blocks and it's done!

Spare Parts (I): Dashboard ...

23 January 2020


Quite a few spare parts aren't available anymore and taking "old ones" actually doesn't help, as they are most likely in the same state.

The first - of many - I want to report is the flap inside the outside dashboard air vents. As you can see on the first photo, everything's broken and the rubber is hard and damaged. So I tried to design that flap, including a "negative form" to produce my rubber myself.

After some test prints (in white; that increases the contrast when you want to see where the collisions are), the thing fit.

The rubber thing I started with the rear Pick-Up lights. That sealing isn't available anymore. So after a lot of trying (and spending money) I found components, that give me a rubber roughly in the consistency of the original one. You mix the stuff, put it in the negative form and after approx. 3 hours you can take it out.