The tubing is pieced together by us from aluminum tubing available on the Internet, especially the large tube across from one side to the other. We didn't use any of the info from "Reproduce Almost Anything" to make any of the iontercooler installation.

I did use my experience with fiberglass to construct the fiberglass plenum placed inside the passenger-side fog light opening.

We tried very hard not to chop or drill anything MB. I believe that we had to drill about eight 1/4 inch holes in sheet metal but that's about the extent of our changes to the non-replacable car parts. We did obviously cut some material away on the headlight frames but we could easily replace those parts to go back to stock if we wanted to.

Stand by for another picture as Gordon has gone out to photograph our boost agae installation.

Ben
www.reproduce100s.com

Tank,

If you're talking about my how-to videotape/workbook, "Reproduce Almost Anything" as a result of going to www.reproduce100s.com , yes, that's my product and it's intended for anyone who wants to produce inexpensively metal, plastic, rubber, ceramic copies of any original part.

Obviously, owners of very old MBs could use such an instructional product.

Ben
www.reproduce100s.com

Here's where the boost gauge was placed.

Quite an amazing fit (Not to mention fun to watch in action!!!!), and...

One can actually adjust the guages 'angle' to better face the driver (for height/preference). Very similar to how one adjusts the standard air vents.

Ben

Attached Thumbnails

 

Thought this angle might be of interest to some...

One can see better, how we covered the "Naked" Turbo with a blue anodized (curved) plate of aluminum. We knew that a "chrome plate" would have made the car even faster, but the blue just looked better!

Attached Thumbnails

 

VERY impressive!

What made you choose that style of intercooler? Couldn't you have mounted one under the car below the radiator?

You should take your car to the track and see what it does in the 1/4 mile.

Our selection of intercoolers was dependant on several things. 1. Cost, we picked this one up in the local newspaper for $75.00. 2. It fit the area that we liked. 3. The intercooler mounted under the front end is very susceptable to damage from curb strikes and they run somewhere from $400.00 to $800.00. 4. The under the front intercoolers also have long tubing to connect and as a result large pressure drops and turbo lag.

While we'd like to find out just how fast this thing is, we don't envision taking it to the drags because of the possibility of blowing a transmission, etc. Our initial runs show that it's very easy to over boost if one tries to accelerate too fast. We're really more interested in having the power in an emergency, getting better fuel mileage and most importantly reducing the cooling load on the 300DT.


Ben
www.reproduce100s.com

I don't think there is any need to worry about this transmission, unless you are having problems with it. If I'm not mistaken this same 722.3 tranny was used in the 280E, which in europe had 180 or 200hp.

I look forward to my updates to this thread. Do you think it will be applicable to my 85 300 SD?. Great Job!.
Alan

__________________
92 500E Silver 66k
82 Porsche 911SC 84K
68 Cadillac ( Gone Now )
03 Suburban Z71 200K
85 300SD 217k From Original Owner ( Dad )

Beastie,

Since the 85SD has the same engine and probably has the requied intake manifold as shown in the pictures, I can safely say that it could be intercooled with the same size intercooler. I don't have access to a SD so I can't tell you whether the intercooler would fit in the same location just behind the right side fog light. In fact, I'm not even sure whether the 85SD has a fog light!

Ben
www.reproduce100s.com

the 85 SD has one sealed beam square light one side and then a regular fog light built in like a 300E, so it would look kinda funny if you took the headlight door off. The 300D w123s are the best for taking out the fog light. there are always other options for ducking air.

__________________
Current Stable:
1994 S500 v140, 210k miles, white with grey.

Former Mercedes in the Stable:
1983 300CD Turbo diesel 515k mi sold (rumor has it, that it has 750k miles on it now)
1984 300CD Turbo Diesel 150 k mi sold
1982 300D Turbo Diesel 225 sold
1987 300D Turbo Diesel 255k mi sold
1988 300 CE AMG Hammer 15k mi sold
1986 "300E" Amg Hammer 88k mi sold (it was really a 200, not even an E (124.020)
1992 500E 156k mi sold
etc.

The idea of being able to install an intercooler is tempting me to get a turbo model. What should I look for in a car, if I want to do it the most cost effective way?

Actually, I was thinking that myself...wondering where a good alternative spot would be to suck the air in for the intercooler and for the air intake. I think the idea's cool overall, but it'd be nice to keep the foglights...although I don't currently use them, I'm thinking on the lines of wiring them in with the high beams someday...and getting white lights for the lenses (actually, "lens") although I rememebr hearing that there is a sealed-beam unit that'll fint in the hole...

__________________
2001 VW Jetta TDI, 5 speed, daily driver
1991 Ford F-350, work in progress
1984 Ford F-250 4x4, 6.9l turbo diesel, 5 speed manual
Previous oilburners: 1980 IH Scout, 1984 E-350, 1985 M-B 300D, 1979 M-B 300SD, 1983 M-B 300D
Spark-free since 1999

123C,

Don't get another car, the most economical way to go would be to get a turbo engine for your Coupe. While you're at it equipe it with a 240D tranny!!

Ben
www.reproduce100s.com

I have to look at my Dad's 85 SD again but I believe that I can duct the air for the intercooler from beneath the bumper where the engine preheater cord is currently stored. My father is the original owner of the car and I have been hounding him relentlessly to sell it to me. It was repainted 2 years ago ( pearl Black ) and has been flawlessly maintained.
Alan

__________________
92 500E Silver 66k
82 Porsche 911SC 84K
68 Cadillac ( Gone Now )
03 Suburban Z71 200K
85 300SD 217k From Original Owner ( Dad )

Ridge,
I have thought about swaping in a turbo engine before, but have decided that I want to have a sedan in addition to my coupe. I figure that I can get sedan with a turbo and try this installation.