We took out our rear window on the '83 today to see what the damage from rust was and to take care of it, and this is what we were met with (beware, many pictures) the HORRORS

Any help or suggesstions on how to deal with this would be very very much appreciated.

Here they are:

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__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)

More Pictures:

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Even more:

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Help on this????

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sand, apply POR-15 rust killer, then weld like metal or worser use fiberglass to build up.

i feel for ya! i wonder what is under my sd rear glass?

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1993 Mercedes Benz 300D 2.5 205K (ex wife's)
1984 Mercedes Benz 300SD 320K (SOLD)
2004 Mercedes Benz C240 75K
1995 GMC Sierra 2WD 5.7L 188K
1983 Mercedes Benz 300SD 239K (SOLD)
1987 BMW 325i 220K (SOLD FOR SALVAGE)

609 Certification

grind, weld and POR-15. Don't be afraid to cut the rust out, it has to go. You don't have to duplicate the old metal exactly though. Mig in strips where inside and outside panels are pointing AT each other, then butt weld PERPENDICULAR another strip the thickness of the 2 pieces where they are spotwelded together. Yeah, it's work, but it's probably a lot more doable than you think.

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'82 300SD - 361K mi - "Blue"

"Good judgement comes from experience. Experience comes from bad judgement."

listen, look, .........and duck.

I also found the same thing on my 83sd, rear window leaking, removed the window and I just about freaked out but my auto body guy said,"relax" and as Pete Burton said" It is more doable than you think". The auto body guy took an air powerd wizzer and proceeded to cut out all the cancer. He left high spots where ever he could so the glass would sit right. Then he formed 2 pieces of L stock together and bent to fit. He then fit it so it becme the pinch weld where the glass sits, he drilled sm holes in the base of the L and pop rivetedon to the body, he then put some sort of smoo or body gooo, and reassembled it and installed the glass. That was almost 2 years ago and no leaks. steve 83sd

My eyes, my eyes! That's a very unpleasant image ...

Step 1: shop vac
Beyond that, I'd say get some products from POR15. Marine Clean, Metal Ready and then POR15 SILVER ... I ordered their "starter pack," but I would say you need more than that. As for welding/building up, I can't tell you a thing (I'll let the other guys help ya there), but whatever bare metal youre left with, clean with Marine Clean, prep with metal Ready and then paint over two or three layers of the silver POR15. I don't think you need to put a coat of primer or paint over top that, since the area isn't exposed to much sunlight, right?

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1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

P.S. ... that's what my entire 240D looks like!

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1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Holy molly you got your work cut out for you I do have to say that...

__________________
Proud owner of ....
1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
1987 GMC 3/4 ton 4X4 Diesel
1989 Honda Civic (Heavily modified)
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Section 609 MVAC Certified
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"He who fights with monsters might take care lest he thereby become a monster. And if you gaze for long into an abyss, the abyss gazes also into you." - Friedrich Nietzsche

Now your going to make me pull my rear window to check. One more thing on the list.

__________________
Adam Lumsden
(83) 300D
Vice-President of the MBCA International Stars Section

Thanks for all the comments and suggesstions, The guy at the glass place said "thats going to cost like $5000 to fix!" So my dad went: Good thing I can assure him it most certainly will not. That guy must have been crazy......or he just knows about glass and not body/rust-repair...he did a good job getting the window out intact.......we'll look into the solutions you all mentioned here, thanks!!

__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)

Repair shops see the MB star and dollar signs light up in their eyes.

Cut out the rust, sandblast what you can't cut out, MIG weld in replacements. Prime with epoxy and paint. Visit your local body shop supply store. Visit your local junkyard for sheetmetal.

Don't buy rusty cars.

I'm almost certain I'm going to find the same thing on my 300SD. It has rusted through on the underside of the window in the trunk so I can only imagine what the lip where the window sits actually looks like. My 380 leaks too after replacing the rear glass, but its in the garage for the time being.

I wonder if someone had already pulled the glass out to find a mess like that and just put the glass back in. The rear seal looks kinda new but I have a new one ready to go just in case. It was missing the chrome window trim too when I got it, but I have since picked up a set. Would not having that rear trim in place be enough to cause it to leak? I can definitly push on the glass in the corners and see it move...

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1980 500SE/AMG Euro
1981 500SEL Euro
1982 380SEL
1983 300TD
1983 500SEC/AMG Euro
1984 500SEC
1984 300TD Euro
1986 190E 2.3-16
1986 190E 2.3
1987 300D
1997 C36 AMG
2003 C320T 4matic

past: 1969 280SE 4.5 | 1978 240D | 1978 300D | 1981 300SD | 1981 300SD | 1982 300CD | 1983 300CD | 1983 300SD | 1983 380SEC | 1984 300D | 1984 300D | 1984 300TD | 1984 500SEL | 1984 300SD | 1985 300D | 1986 300E | 1986 560SEL | 1986 560SEL/Carat | 1987 560SEC | 1991 300D 2.5 | 2006 R350

When I did mine 2 years ago, $100.00 to the window man, to pull and replace and $89.00 for the MB window seal and $150.00 to the auto body man to fix it. steve 83sd