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  #31  
Old 06-10-2017, 10:37 PM
BodhiBenz1987's Avatar
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Originally Posted by Diseasel300 View Post
The biggest challenge I had with getting the SDL back on the road was the sheer number of things that had to be done. I had a hard time getting any one thing taken care of and didn't really have a direction to go.

What really helped me out was setting out a plan with a prioritized list of what needed to be done and in what order. As I went through, I crossed things off. It seems like a small thing to do and perhaps a waste of time to someone else, but it did help me and gave me a sense of accomplishment. Towards the end, I started getting a momentum and challenging myself to cross extra things off the list ahead of schedule. That's when it starts to become fun.

Now that I have the car back on the road, I've been using it in daily-driver duty for the last few weeks and it's been very rewarding.
I think making a list might be helpful for me too at this point. That's really been a hard thing, just having all these things I need to do in my mind and getting overwhelmed. I need to break it down into smaller jobs and focus on one at a time. The challenge in the area I'm in now is that there are a lot of layers involved, so I have to figure out logistically which layer I have to do in what order. But I think if I make a list, I can circle one thing and say "I'm doing this" and not worry so much about what's next on the list. I think it might make each part feel like more of an achievement, rather than a drop in the bucket.

I think whenever I get the wheel wells, suspension mounts and rockers done, that's going to feel like a bit step. It stresses me out a lot as there is (in my mind at least) a lot of room for misaligning something or having it look wrong. Once that part is finished, the rest is more a lot of little things that can easily be broken down into smaller tasks.

__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)
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  #32  
Old 06-10-2017, 10:46 PM
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Originally Posted by jake12tech View Post
A lot of effort putting this car back together. I appreciate it. I built my own control arm mount for both sides on my 92 300d. I wasn't paying the price of the dealer or classic center when I know I can build something better. I also had to weld the wheel wells.. I got SUPER lucky the rockers weren't rotted. I cleaned up the surface rust and POR-15'd them and slapped the rocker cover back on them.

Also, don't worry about your welds being pretty.. As long as they're penetrating and strong that's all that matters. If you grind it down, you will never know how ugly they were. But your welds are great for a beginner/intermediate welder. Pretty welds come with time, but don't worry about that now as long they stick good and don't burn through.
I ended up ordering the suspension mount points from MB. The classic center had to add them into the system. Not a popular item I guess, haha. It was probably stupid to pay for new ones when I could have made them, but the price was decent enough that to me it was worth making it a bit easier. For the inner fender and other areas I can just cut out sheet metal, or cut from my parts car. I really am having a hard time convincing myself to cut up my parts car because it's such a nice-looking car and of course I want to save it too.

Luckily most of my welds will be hidden or hard to see, which helps me feel a little better. I will have a weld on the very visible part of the fender on both sides as well as one area farther back on one fender that I have to make a patch (dent that rusted a little ... POR15 really held that at bay for 10 years though, didn't advance at all). So those welds I'm a little more worried, even though they'll be ground. I did do the corner of a fender last year and it actually came out really nice despite the welds looking awful. I didn't quite get it even with my filler job, but can redo that before I go to paint the car.
__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)
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  #33  
Old 06-11-2017, 09:02 AM
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Quote:
Originally Posted by BodhiBenz1987 View Post
I ended up ordering the suspension mount points from MB. The classic center had to add them into the system. Not a popular item I guess, haha. It was probably stupid to pay for new ones when I could have made them, but the price was decent enough that to me it was worth making it a bit easier. For the inner fender and other areas I can just cut out sheet metal, or cut from my parts car. I really am having a hard time convincing myself to cut up my parts car because it's such a nice-looking car and of course I want to save it too.

Luckily most of my welds will be hidden or hard to see, which helps me feel a little better. I will have a weld on the very visible part of the fender on both sides as well as one area farther back on one fender that I have to make a patch (dent that rusted a little ... POR15 really held that at bay for 10 years though, didn't advance at all). So those welds I'm a little more worried, even though they'll be ground. I did do the corner of a fender last year and it actually came out really nice despite the welds looking awful. I didn't quite get it even with my filler job, but can redo that before I go to paint the car.
How much were the mounts? Also, what kind of parts car is it? Another 87 300d? I wouldn't bother cutting out the sheet metal.. Start learning how to fabricate, it's much better than just cutting and welding from a parts car essentially.. Plus that that metal you know what it already looks like and doesn't have undercoating and paint to hide corrosion.
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Only diesels in this driveway.
2005 E320 CDI 243k Black/Black
2008 Chevy 3500HD Duramax 340k
2004 Chevy 2500HD Duramax 220k
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  #34  
Old 06-11-2017, 01:13 PM
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Originally Posted by jake12tech View Post
How much were the mounts? Also, what kind of parts car is it? Another 87 300d? I wouldn't bother cutting out the sheet metal.. Start learning how to fabricate, it's much better than just cutting and welding from a parts car essentially.. Plus that that metal you know what it already looks like and doesn't have undercoating and paint to hide corrosion.
They were I think $110 on each side, plus $60 for the plate it bolts into (not sure why they come in two parts, maybe easier to line up?). I'm sure it doesn't make any difference, but the fact it's a suspension mount point gives me (maybe irrational) anxiety about fitment and whatnot, so I look at the cost as a mental health investment. I also bought the front spring perches new for the same reason. And the rocker panels because there's no way I'm fabricating an entire rocker panel at this point! I'd love to learn all components of restoration at some point, but since I just learned welding, and just learned painting, I gave myself a pass to just buy the panels that I felt mattered most in terms of structure.

For some areas I'll definitely go for new sheet metal (I already did for a couple spots in the front wheel well and floor) but I'm concerned about areas that have a very specific and multi-directional bend, like where the inner wheel well tucks under the outer wheel well. I'll certainly try.

The parts car is a 93 300E wagon. I originally bought it to use the rocker panels, but it turned out there is rust on part of one. When I found out I could order them, I just did that. The body is mostly really nice, aside from one dented fender. It's beautiful green. The engine wouldn't run, even after a rebuilt head. I got the car from Hogweed here on the forums. It has a lot of good parts and is a mostly complete car.
__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)
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  #35  
Old 06-11-2017, 07:47 PM
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Quote:
Originally Posted by BodhiBenz1987 View Post
They were I think $110 on each side, plus $60 for the plate it bolts into (not sure why they come in two parts, maybe easier to line up?). I'm sure it doesn't make any difference, but the fact it's a suspension mount point gives me (maybe irrational) anxiety about fitment and whatnot, so I look at the cost as a mental health investment. I also bought the front spring perches new for the same reason. And the rocker panels because there's no way I'm fabricating an entire rocker panel at this point! I'd love to learn all components of restoration at some point, but since I just learned welding, and just learned painting, I gave myself a pass to just buy the panels that I felt mattered most in terms of structure.

For some areas I'll definitely go for new sheet metal (I already did for a couple spots in the front wheel well and floor) but I'm concerned about areas that have a very specific and multi-directional bend, like where the inner wheel well tucks under the outer wheel well. I'll certainly try.

The parts car is a 93 300E wagon. I originally bought it to use the rocker panels, but it turned out there is rust on part of one. When I found out I could order them, I just did that. The body is mostly really nice, aside from one dented fender. It's beautiful green. The engine wouldn't run, even after a rebuilt head. I got the car from Hogweed here on the forums. It has a lot of good parts and is a mostly complete car.
Get that wagon a space in the garage and ill help make sure its a parts car

P.S. I washed my wagon this afternoon and realized (again) there is no way I can sell it...
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  #36  
Old 06-11-2017, 10:12 PM
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Quote:
Originally Posted by BodhiBenz1987 View Post
They were I think $110 on each side, plus $60 for the plate it bolts into (not sure why they come in two parts, maybe easier to line up?). I'm sure it doesn't make any difference, but the fact it's a suspension mount point gives me (maybe irrational) anxiety about fitment and whatnot, so I look at the cost as a mental health investment. I also bought the front spring perches new for the same reason. And the rocker panels because there's no way I'm fabricating an entire rocker panel at this point! I'd love to learn all components of restoration at some point, but since I just learned welding, and just learned painting, I gave myself a pass to just buy the panels that I felt mattered most in terms of structure.

For some areas I'll definitely go for new sheet metal (I already did for a couple spots in the front wheel well and floor) but I'm concerned about areas that have a very specific and multi-directional bend, like where the inner wheel well tucks under the outer wheel well. I'll certainly try.

The parts car is a 93 300E wagon. I originally bought it to use the rocker panels, but it turned out there is rust on part of one. When I found out I could order them, I just did that. The body is mostly really nice, aside from one dented fender. It's beautiful green. The engine wouldn't run, even after a rebuilt head. I got the car from Hogweed here on the forums. It has a lot of good parts and is a mostly complete car.
That isn't as bad as I'd expect for the parts. I guess worth it in your case if you have anxiety about fitment and alignment issues. It's better to be safe than sorry I guess. Yeah, Gregg was telling me about that car before. What a shame. I'd love to know why it doesn't run. Something wasn't put together properly after the head rebuild.
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Only diesels in this driveway.
2005 E320 CDI 243k Black/Black
2008 Chevy 3500HD Duramax 340k
2004 Chevy 2500HD Duramax 220k
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  #37  
Old 06-11-2017, 11:12 PM
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Originally Posted by gatorblue92 View Post
Get that wagon a space in the garage and ill help make sure its a parts car

P.S. I washed my wagon this afternoon and realized (again) there is no way I can sell it...
You're never going to sell that, it has too much individuality.

Cleaning a clear path and space in the garage is almost as daunting as the repairs I'm doing, haha. Hoping to have some more time soon, though.
__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)
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  #38  
Old 06-11-2017, 11:25 PM
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Originally Posted by jake12tech View Post
That isn't as bad as I'd expect for the parts. I guess worth it in your case if you have anxiety about fitment and alignment issues. It's better to be safe than sorry I guess. Yeah, Gregg was telling me about that car before. What a shame. I'd love to know why it doesn't run. Something wasn't put together properly after the head rebuild.
I just have a lot of anxiety in general, it's kind of a miracle I'm even trying this project and got this far with it. I am a supreme overthinker. But, hopefully I end up with a repair I'm confident in, and it will definitely be worth it to me.

That's what frustrates me about the wagon ... the nagging feeling there might be something fixable. It did sit for a fairly long time now, so it would be more than an engine to get it back on the road. I knew this would happen when I tried to get a parts car ... it breaks my heart. I mean I realize it's not a sentient being, but still. Gatorblue is going to have to be the tough one since some of the parts are his.
__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)
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  #39  
Old 06-11-2017, 11:39 PM
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Some stuff I did over the weekend. Pulled out the subframe. When I did the bushings and linkage about 7 years ago I took forever to get the subframe out, I thought I could never do the job. So I guess it's some progress that now it was pretty easy and I got it out in a day. I also wire wheeled some undercoating to find where the rust ended and was glad to find clean metal eventually. Today I didn't have much time but I played around with a hvac housing I've had sitting around for ages, hoping to figure it out before I do the evap on my car. It confirmed I really do not want to do that job, but it seems silly to not refresh the possibly leaking evap when at least half the labor is already done. I'm also attaching a picture of the other side rear jackport, which is the worst but I did find clean metal when I got inboard a bit, so I know what I have to rebuild.
Attached Thumbnails
1987 300D (Bodhi) rolling restoration-18952589_10100529420339229_5094214149819485297_n.jpg   1987 300D (Bodhi) rolling restoration-18952949_10100529507978599_8516097235283201384_n.jpg   1987 300D (Bodhi) rolling restoration-19105954_10100530076584109_576667055425612316_n.jpg   1987 300D (Bodhi) rolling restoration-18953100_10100529508243069_4414474811099060680_n.jpg  
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1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)
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  #40  
Old 06-15-2017, 09:20 AM
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Bodhi, I've done small sheet metal repairs on the rockers of these cars and w210s a few times. I've acquired a "free" 87 300D I traded a lot of my time for in return for the car. I had it on a lift yesterday and discovered some substantial rocker rust. I was going to replace quite a bit of the rocker due to rust with a spare outerskin i have. Did you reinforce anything on the rocker? Or recommend it? I saw a previous post of yours about rocker repair.
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Only diesels in this driveway.
2005 E320 CDI 243k Black/Black
2008 Chevy 3500HD Duramax 340k
2004 Chevy 2500HD Duramax 220k
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  #41  
Old 06-17-2017, 09:19 PM
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Originally Posted by jake12tech View Post
Bodhi, I've done small sheet metal repairs on the rockers of these cars and w210s a few times. I've acquired a "free" 87 300D I traded a lot of my time for in return for the car. I had it on a lift yesterday and discovered some substantial rocker rust. I was going to replace quite a bit of the rocker due to rust with a spare outerskin i have. Did you reinforce anything on the rocker? Or recommend it? I saw a previous post of yours about rocker repair.
I haven't actually tackled the rockers yet (other than some very aesthetic-only fiberglass coverup a few years ago), since I have to do some of that rear wheel well first, and I'm just super slow, at everything. Have not even touched the car in a week because I got sick, ugh.

But, in terms of bracing, what I've been hearing from everyone I ask is, there is no need to brace as long as the inner sill is really solid, and you are only removing the outer sill. I got nervous anyway (as always), so I ended up welding braces in the doorways, which on hindsight I'm not sure are the least bit purposeful. I just put them about halfway up the A/B/C pillars between A-B and B-C. I just welded on angle iron and will grind it off later.
__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)
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  #42  
Old 07-28-2017, 09:22 AM
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Photos

Bodhi. What are you using for photo hosting now that the photobucket has gone nuts?

- Peter.
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2021 Chevrolet Spark
Formerly...
2000 GMC Sonoma
1981 240D 4spd stick. 347000 miles. Deceased Feb 14 2021
2002 Kia Rio. Worst crap on four wheels
1981 240D 4spd stick. 389000 miles.
1984 123 200
1979 116 280S
1972 Cadillac Sedan DeVille
1971 108 280S
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  #43  
Old 07-30-2017, 02:37 PM
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Originally Posted by pj67coll View Post
Bodhi. What are you using for photo hosting now that the photobucket has gone nuts?

- Peter.
I have to figure that out, ugh. I guess for now I will just attach them here, but at some point I need to go back and edit my previous posts which is a pain! I can probably upload some to my WordPress blog (which I don't blog on anyway) but I'm not sure if there's a limit there too.

Working on rebuilding the inner rocker and wheel well now, kind of a puzzle. I cut one piece out of a parts chunk, next piece I'm going to try to make. Sometimes it's an easier fit from a parts car, but it's double worst part of the work (disassembly, cleaning off coating, cutting/drilling, cleaning off more coating). I bought a set of shrinker-stretchers which I'm looking forward to playing with but don't have a bench to bolt them to.

As usual I'm moving super slow, put it on hold a while because I went to England for a week (and drove a nice little 6-speed diesel on the "wrong" side of the road, a fun challenge!).
__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)
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  #44  
Old 01-11-2019, 07:10 PM
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grind a way all paint not weld try paint and ,try to get panel thigt .add seam sealer before paint

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