w123 Floor Rust repair - Page 15 - PeachParts Mercedes-Benz Forum

martureo · #**211** 07-24-2023, 07:49 AM

Quote:

Originally Posted by vwnate1

I don't understand ~ I just make a schematic of the colors of the wires where they go into the plug then open the plug so the wires with their soldered on barrels can be threaded through the same holes.......

Oh, the wires have number markings on them and numbered tags on them. It couldn't be easier to figure out which one goes in which plug.

But there's no way to get the soldered connector through the plug housing.

martureo · #**212** 08-01-2023, 09:18 PM

Driver's floor is painted, plugs added and Kilmat added.

martureo · #**213** 08-01-2023, 09:19 PM

Continued.

martureo · #**214** 08-01-2023, 09:35 PM

A slight diversion while I'm waiting for some paint to dry.

The little footrest for your left foot in the driver's footwell has been something I've loved for years. But during this repair I got to collect the various pieces it's ended up in, hoping that they'd find their way back together.

I figured out that the plastic is polystyrene, which gave me hope that it might be glued back together with epoxy. (Some plastics really don't take to gluing).

As the fractures were mostly along the lines of the strengthening ribs, I wanted to add a few extra ribs to ensure they wouldn't break in the same place again. I went with 1/8" acrylic after some debate as I thought steel would rust (and I'd have to paint it) and aluminum would be more expensive than necessary.

I cut a few notches in the existing ribs and then sanded all the surfaces before gluing.

The first bits after drying.

martureo · #**215** 08-01-2023, 09:38 PM

The next biggest pieces were difficult to work with, so I drilled out the rivets holding the side panel.

Rather than going with the ribs as before I decided to go with flat reinforcing pieces, partly because of the missing bit that I'd try to fill in later.

Time will tell if this holds up well.

vwnate1 · #**216** 08-02-2023, 10:56 AM

Nice ! .

I like your gusseted repair job .

unkl300d · #**217** 08-02-2023, 05:34 PM

Excellent !!

That car won't disappoint!

martureo · #**218** 08-14-2023, 09:19 PM

Interior bits are taking a bit longer to put back than I anticipated, so I've been working on more side jobs that still need to be done.

One that I tackled which I thought would be quick was to clean and refresh the blower motor. The rotor was grooved but I thought I could just replace the brushes and clean the squirrel cage. Nope. I couldn't find anyone in my area who would sell me brushes that I could modify. Even Ace Hardware wanted me to wait a week and they'd need to ship them to the store to see what size they were.

Looking at my options I could go with the URO blower with a new squirrel cage and housing for ~$150, I could order some brushes for ~$20 or find a new OEM blower for +$300. I chose to go another route and used a tip on a forum for a replacement Bosch motor from a different application. (Found one on Ebay for $50).

Here's the difference. The original motor is on the bottom, the new on the top. The new motor has a shaft 10mm longer and without a spline. Other than that its identical.

Here's the new one installed on the old fan. I pushed it down so that the extra length is 10mm through, and this doesn't seem to interfere with the housing in the car.

Just for reference, the old motor part number is 0 130 111 103 . The new motor is also a Bosch unit, part number 0 130 111 134.

cfh · #**219** 08-15-2023, 01:38 PM

You wrote the Bosch blower motor was for a different application. Could you tell us what that was? Thanks!

unkl300d · #**220** 08-15-2023, 01:40 PM

The new one has a smooth shaft. No spline.

How did you secure the squirrel cage?

Nice hack. Thanks for sharing.

p.s. can you dissect the old motor and measure the brush size?

martureo · #**221** 08-15-2023, 03:06 PM

Quote:

Originally Posted by cfh

You wrote the Bosch blower motor was for a different application. Could you tell us what that was? Thanks!

Volvo 850 2.3L or 2.4L 1993-1997

martureo · #**222** 08-15-2023, 03:11 PM

Quote:

Originally Posted by unkl300d

The new one has a smooth shaft. No spline.

How did you secure the squirrel cage?

Nice hack. Thanks for sharing.

p.s. can you dissect the old motor and measure the brush size?

Since the spline was cut into the shaft it had a reduced diameter from the rest of the shaft. I worried that I wouldn't be able to press the fan onto the shaft, but I measured the reduced diameter and it seemed reasonable for an interference fit. As a backup plan I though of drilling the fan to a larger diameter if pressing it on took too much force, but it went on relatively easily.

I don't think I'll have to secure the fan by another means, the interference fit should be good enough. If, for some reason, I notice that its spinning on the shaft (I think I'll have other problems before that), then I'll probably cut the extra length off and cut a notch in the end to insert a metal tab.

I'll update this with the brush sizes when I get home.

unkl300d · #**223** 08-15-2023, 07:05 PM

I wonder whether loktite 609 would help..

martureo · #**224** 08-16-2023, 06:54 PM

Another few small things as things keep moving in the right direction.

I replaced the brake pedal pad as it was pretty cheap ($12) and the old one wasn't feeling good about everything around it getting renewed.

123 291 00 82

I'm pretty amazed at the wear.

Not sure if they changed the material, but they definitely updated the mold.

martureo · #**225** 08-16-2023, 07:06 PM

These cable channels were driving me nuts as I didn't preserve the holes used to mount them (which were cut out in the rust repair). I finally positioned them in the place I thought fit best and drilled out the holes for the plastic rivets with 7/32" bit.

The part number the the rivets is 000 990 94 92

I bought three different hoses for the evaporator drain, but the only one that I was able to wedge under there was a 1-1/4" OD 1" ID. I tried to get a hose clamp in there, but it was beyond the reach of my patience. The mosquitoes were eating me alive.

Carpet and trim are going in. Its starting to look like an interior again.