I have read about this before and I think I saw a thread a while back where someone was making and sticking these things in a piece of wood. I would rather find someone to fabricate and make the "key end" out of a piece of wood than try to "deal with the dealer" again.

I have only had this damn key for a year and the key (metal) is twisting out of the plastic. The key itself is incredibly strong and looks the part. But, the loop that goes onto the key ring is a complete joke.

Can I inject epoxy into the broken area? Or is this terminal?

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AJ

1985 300D (SOLD)

it's steel, you could weld a key fob to it.

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

You can buy the plastic part of the key separately.

Someone over on another forum made a mold out of the OEM key and a new plastic key head. Then they took the metal part of the key and put it in the mold and they used some very hard black resin to form a new key head that will not break. Very good idea IMO, im going to do it one day. Until then i'll just keep buying key heads for both my cars...

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1985 300TD Turbo Euro-wagon
1979 280CE 225,200 miles
1985 300D Turbo 264,000 miles
1976 240D 190,000 miles
1979 300TD 220,000

GONE but not forgotten
1976 300D 195,300 miles
1983 300D Turbo 175,000 miles

http://i42.photobucket.com/albums/e3...e485-1-2-1.jpg

I was thinking of making one out of jbweld, and por-15... what kind of "resin" would you use?

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

That is good to know! Thanks for that.

More money for more garbage IMO... I do not see the point in that.

I live on the water and their are lots of boat and sailing shops around here.

79Mercy and VStech are onto something. I think I will make one out of a piece of Kevlar or Carbon fiber and resin.

I have found a few problem areas on this car. When I find them, I try to make ti better than before (if possible). This looks like one of those areas. Thanks for the input!!

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AJ

1985 300D (SOLD)

My keys are original and show no signs of failing yet.
Am I missing something here?

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DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

The original ones hold up great. It's the newer ones you get from the dealer that suck.

I ended up making a wood key head. It's not too hard. I cut a rough cut piece of wood in half, and carved out the slot for the top of the key. Then glued the two halves back together. Then shaped it, sanded it, and finished it.

Here is a thread with some pics.
Wood Key

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I've made my dealer replace mine a few times. Figure it has a warranty like anything else. The place in AZ has the the plastic bits for 5.65. I bought a couple when I ordered stuff recently.

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1985 300D cali 190K

http://mercedes.thatchermathias.com/mw300d.jpg

If we all make the dealers replace the ****ty plastic key heads UNDER WARRANTY ,sooner or later the bean counters in Germany will drop the
LOUSY Plastico Key Head supplier!

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'84 300SD sold
124.128

we've got tons of casting supplies at work. I'd probably use a two part hard plastic. Just tint it black and viola

Next time one of you makes a resin/plastic key head . . . can you make extras? I need one too, and in the meantime, I'll go to Key Motors and have them replace the head. How much do they cost, incidently?

Torie

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1983 300D, the "Avocado"
1976 240D, 4-spd the "Pumpkin", SOLD to Pierre
1984 190D, 2.2L, 5-spd, my intro to MBZ diesels, crashed into in 2002

the best way to do this would be to have the mold for the head incorporate the key itself so its bonded as one.

or at least try to make the mold so the key can be inserted and epoxied in

Yes you can, and it often doesn't last. I'm starting to make replacements using a 3/8" diameter piece of aluminum or steel into which I cut a slit with a hacksaw, then slide the key inside.

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Strelnik
Invest in America: Buy a Congressman!

1950 170SD
1951 Citroen 11BN
1953 Citroen 11BNF limo
1953 220a project
1959 180D
1960 190D
1960 Borgward Isabella TS 2dr
1983 240D daily driver
1983 380SL
1990 350SDL daily driver alt
3 x Citroen DS21M, down from 5
3 x Citroen 2CV, down from 6

I also made a wooden fob that I epoxied the key into. Of course that being the original key, the original tumbler started to lock up so I bought a new aftermarket tumbler and now have 2 keys, the new one for the ignition and the original for the doors. I imagine the new key plastic will eventually fail.

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1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily