Rust on rust (not for the squeamish!)
 

Just thought I would share my overwhelming rust repair project with others. Also any pointers are appreciated.

My tactic is to sand it down to bare metal, weld in patches where I can, spray it with rust converter to get any trace amounts of iron oxide, fiberglass/ bondo smaller areas, prime and paint.

Wow that looks good!

I'd most certainly remove the whole sun roof - tray included to see what bits can be saved up there...

As the rear pillars (next to the rear windscreen) I'd take a very very good look at the underlying structure and see if it is worth repairing. And I mean like the whole car. The back end of the W123 is pretty complex there...

I've posted some pictures in this thread showing most of the bits there - it isn't an easy are to fix in my opinion.

http://www.peachparts.com/shopforum/body-repair-restoration/303669-my-w123-saloon-sedan-old-accident-repair-bit-rust-repair-thread.html

Ya i have most of the stuff out of the way for the sun roof to come out. It looks salvage able, but it may be worth my while to find one that doesnt have a hole in it in the junk yard. :eek:

This is a w115 by the way,, :D , but never the less I will look further into the underlying structure and see what the damage could be. while replacing the rear windoseal yesterday I did not find as much rust as I had expected to, next to nothing in and around that lip/ gutter area. I did bang away on the rear door frame and it sounded pretty solid.

The worst of the rust is on the drivers side rear. It originated from the little holes that have plastic insert which the chrome trim pops into. The rust on the bottom of the car was caused by that silly under carriage rubberized coating which trapped water up against metal. Then again it was more likely the person applying the stuff to be blamed than the actual rubberized coating.

The rubberised coating was put there by Mercedes it is such a pain in the arse that stuff

By the way sorry I didn't detect a W115 - oh well! You'll need to do some investigating work for yourself. I wouldn't be surprised if they were built in a similar way...

That's pretty bad, but it could be worse. Check this out: 1973 280CE 4 speed restoration.

Really??? (grumbling) Mercedes put that rubberized coating! :mad:

From what I have heard and seen, rubberized coatings can cause rust because water gets up in between the coating and the metal. Especially if one is using a high power sprayer.

After thumping around on the metal all off the rust seems to have not affected the car in any structural way.

Wow! You're right! It could be much worse. I feel a little better now about my purchase/project. :eek:

Don't get misled by Al and Army. THOSE guys seek out those rust buckets!:D Not all rust repairs on Benz are as extensive as what they take on.

Al's car is a rare bird and Army? Well, Army is just a glutton for punishment.

I'm hoping you enjoy the work you are doing to what I would consider a "parts car". I know Army does it for the challenge and the feeling of accomplishment.

I myself think you'd be better off finding a shell and transferring the good stuff from your car into it. I've done quite a few rust repair projects but there are times when I realize that you cant make a silk purse out of a sow's ear. How's about that for good ol' Yankee slang for you, Al and Army?;)

Parts car huh?

Its rather difficult to find a w115 around my area. Especially for the price I nabbed it at. :)

Nonsense, they find me :)

I guess I'm guilty of assuming you are in central California.


Remember the Benz restorer's mantra, "There is no more expensive car than a cheap Benz".;)

Yes sir. Haha

Great. well so far I haven't put an unreasonable amount of cash into it. Just a lot of hours.

This has been haunting me in my sleep. :eek:


I fear the floors are worse than I had expected after punching through with a screw driver in several places, although very isolated and in strange areas.

There are some small spots right behind the drivers seat but not under it, all along the edge on the drivers side back to where the seat mounts is eaten away but not through the "structural" part, just through the floor.

I figure even after I do all the rust repair and get this car up to daily driving condition it will still be cheaper to drive the car per mile than what my truck costs me.

Remember the mantra, "There is nothing cheaper than a cheap Mercedes Benz diesel owner"