It seems to me that it would be "simple" to make a die to press out a small patch panel to go around the jack point. I visualize a metal casting that could be used in a 50 ton arbor press to push out nice neat patches to weld over the hole that surrounds everyones jacking points.

My experience is that the outer rocker panel has little to do with the integrity of the jackpoint itself.

Any takers?

I pop-riveted some galvanised sheet around the left front jack-port on my '84 300TD. The rocker had some significant holes there, hidden with filler, but the inner bracing for the jack-port still appeared sound. I used a hammer to mark the galvanised with a round dimple at the jack-port. Then a sharp screwdiver-blade to cut the hole slightly undersize, with just enough extra metal to work a narrow collar from the galvanised into the edge of the hole.
I haven't yet tested the Mercedes jack, since I carry a short bottle-jack in the tire-well. I was more interested in getting rid of the ugly filler.

Happy Motoring, Mark

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DrDKW

I cut both rocker panels clear off and welded new ones on. It was then that I realised the rocker panel doesnt have anything to do with jacking the car. both front and rear are well braced internally.

Only until the rust inside the rocker spreads to the jack reinforcements. I tried to jack up the rear of my rusty Fintail awhile back with the factory jack, and the whole jack-port literally came off the car!

Happy Motoring, Mark

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DrDKW

the rf jack point on my td was flopping around in a rusty hole. i pulled it out. i was hoping someone made patch panels, but figured i'd pro'bly end up making my own...

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1984 300TD "MAX" 303K+ still going...
fast '70 Chevelle 200k+
home built Shovelhead chopper

I would like to see a patch panel about 8" square, drawn down into a cone shape, with a neat circle cut out of the center that could be welded in place. I've seen several cars with the jack hole fiberglassed over, including one on Ebay right now (1985 190d). Its a common fault, and my point is that it would be an easy fix with the right patch. Nothing says rusted out like a bad rocker, and its unfair since only the sheet metal is involved in the early stages.

You could form this with a hammer, but since all of these 1980 chassis have similiar profiles in this area, can someone fab up a die in the right shape?

As far as fintails go, let's be frank--its 45 years old, and gets to have rusted jack supports! Here in vermont we never see fintails, or anything else that old, unless someone shows up at a car show in the summer with one.

I made patches a number of years ago out of the plastic container that you get the 40 lbs. of cooking oil in. I used that because I liked the curve already in it, it is real quality stuff and glues on like it was made for it. Only thing is, it made it looks good but didn't stop the rust! It is hard to stop rust on a W123 - matter of fact I don't think it can be stopped. A lot easier to work with then metal and you don't have to weld on steel that already has the rust bug.

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Junqueyardjim
Christianity, if false, is of no importance, and if true, of infinite importance. The only thing it cannot be is moderately important. C.S. Lewis



1983 Mercedes W123 240D 4 Speed 285,000 on the road with a 617 turbo, beautiful butter yellow, license plate # 83 240D INDIANA

2003 Jaguar Type X, AWD. beautiful, good mileage,
Mom's car, but I won't let her drive it!