Finishing Samson the M120 R107 - Page 2 - PeachParts Mercedes-Benz Forum

Roncallo · #16 02-09-2020, 01:36 AM

So what I feared most has of course happened. Checked the mounts on Samson and they hit the radiator. Adjusted the offset on the lower mounts 2mm and they still hit. 3 inches worked but leaves only about 0.080" clearance for the fan. So that is too close, fortunately I believe I can fix it with a hammer. It will be hard to swing a hammer on Samson with the engine still in the car but I'm hoping to get a heavy duty zip gun in place. I just ordered this hammer chisel set. I think the 1.25" rounded hammer head will do the trick.

https://www.amazon.com/gp/product/B01JBO4E34/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

These go into a Chicago Pneumatic CP717, it has a **** ton of power. If that works well I may even offset it another 2mm for tolerance issues.

I also moved the condenser 1/2" to the right to give more room for hose routing. You just cant get enough room for that. That required offset mounts

First picture shows the new lower brackets that move the radiator 3mm forward. The second picture shows a comparison between the new and the old. Third picture shows how the brackets are installed. They are clamped for the moment but will be welded in place. The 4th picture shows the modifications I needed to do to the lower radiator adapter pins to move the radiator 1/2" to the right. 5th picture shows everything installed.

Hopefully tomorrow I will be able to work on the fan supports.

Roncallo · #17 02-10-2020, 11:00 PM

Today my hammer tip came in and it just took about 1 minute to get all the clearance I needed. I finished up the top fan mounts but they still need painting. With that under control, I will re- fabricate the lower condenser mounts to move the condenser out another 2mm. Then I just need to fabricate 1 lower plate before I can weld everything in place. I expect to complete the condenser and fan installation by 2-12-2020. Hopefully by the end of the week I will have the Receiver Dryer installed.

Next step will be plumbing to the engine compartment. This will required custom made hard lines. That may take some time to design and order.

After that all work goes right to Samson. The sub frame will need to be removed to fit a custom made Compressor manifold and line set. Samson will be down for a long time at that point. With the subframe removed from Samson measurements will be taken. The subframe will also be fitted into Ebola (My scrap car) and the M113 engine will be test fit in Ebola. Modifications will also be performed that will allow me to lower the M120 engine which had to be raised 1/4" to compensate for settling subframe and engine mounts.

And of course while all that is going on, I need to do a timing chain and turn signal switch on Delilah, my stock 560SL.

t walgamuth · #18 02-10-2020, 11:13 PM

Its looking good!

Roncallo · #19 02-15-2020, 12:04 AM

I got the drier mounted today. Its a bit of a temporary mount as the material I have is too flimsily. I will be ordering some 3/32 steel to make a proper one. But it was good enough for evaluating the required line routing. AC line bending may be a challenge. I need to find someone who can put a 180° bend in a 3/8" tube with a 1/2" center line radius for the drier discharge tube. I also have some fairly close coupling of two out of plane bends required for the condenser inlet line. I have work arounds if those become to difficult but I would prefer to keep it as shown.

t walgamuth · #20 02-15-2020, 08:18 AM

Are all those black lines on the tubing representing welds?

Dubyagee · #21 02-15-2020, 10:25 AM

I think its just delineating the curves

Roncallo · #22 02-15-2020, 01:52 PM

Quote:

Originally Posted by Dubyagee

I think its just delineating the curves

Yup

Roncallo · #23 02-20-2020, 12:25 AM

AC line situation appears to be under control. I spoke with the tube bender today and he says he can do a radius of 2x the diameter of the tube. So that means the best I can do is 3/4" CL bend. So I redesigned with an offset just past the drier. I mocked up the lines and came to the conclusion I have a solution.

Roncallo · #24 03-04-2020, 12:39 AM

Coming down to the ultimate challenge in this AC installation. The manifold tubes off the compressor. As it is one of the things that was in the way on my car was the hydraulic pump portion of the tandem pump mounted on the M120 engine. The cars that were fitted with the M120 all had hydraulic suspension, which Samson does not. Therefore to get around that for the past 10 years I have been running the hydraulic pump into a tiny reservoir form a 2006 Nissan Altima. This allowed hydraulic fluid to circulate around doing nothing but lubricate the front bearing in the pump. For the AC compressor lines and well as the future cold air intakes this reservoir and associated tubing was now in the way. Plus it was such an unprofessional way of addressing the problem so it had to go. I found this to be a simple fix. The M120 ZF pump reservoir will bolt in place of the M119 ZF Pump cap from earlier SL500's and E300's, and they have the same mounting pattern, pulley mount and offset. That was easy, 4 screws for the reservoir and maybe you will have to swap pulleys, and you have a single power steering pump without the hydraulic stage. So I got the pump, rebuilt it and now I'm ready to attack the AC compressor lines.

The installation of the M120 into the 107 required extensive modifications of the 107 subframe especially around the compressor area to allow clearance for the compressor. Needless to say there is not much clearance in this area. When I first looked at this, I was under the impression that either the sunframe or engine would have to be removed to replace the compressor. Looking at it now I believe I will be able to remove the compressor out the front with the radiator and condenser removed. Still not ideal but a lot better than removing the sub frame. In any case that is for the very near future.

In any case the immediate challenge is routing the lines to a compressor that is shoe horned in. This will require making my own manifold. To do that I took my best guess at what the manifold needed to look like and what direction the tubes had to exit. I then 3D printed a plastic model of the manifold and will be testing to see if it bolts in in the very near future, See attached pictures. Preliminary test shows that the manifold hits the subframe at the corner where im pointing to in the last picture but just a 0.020" grind will give it positive clearance. Since the engine rocks on the subframe that clearance will need to be increased significantly. It looks like it can be done. The outlet ports are small for the moment so that if an angular correction needs to be made. It can be done by re'drilling to the next larger tube size.

vwnate1 · #25 03-04-2020, 09:38 AM

If you go into building Hot Rods you'll be at the high end of things, Like Iconic .

Roncallo · #26 03-06-2020, 02:47 AM

Well version two went much better. Based on the information I got out of the first block, I was able to see I nailed it on the angles and with the small tubes I put in the holes I was able to assure myself I had a path out for both suction and discharge lines. With the angles now known I could model it up with the full size tubing and it turns out that the lower tube turns out of the way of the upper tube, allowing me to not have to stagger the holes. So I modeled up the new design along with the tubes. This 3D printing stuff is usefull. Everything falls right in place. Only problem now is finding someone that will mandrel bend the tubes in steel.

vwnate1 · #27 03-06-2020, 08:30 AM

Fascinating .

Roncallo · #28 03-08-2020, 11:18 PM

Quote:

Originally Posted by vwnate1

Fascinating .

Thanks Nate

More 3D printing coming tonight. Just started an 18hr print job of all the lines. Hopefully I got them all right and can send them out to be made.

At this time I now have all parts in house with the exception of the 5 hard lines and the compressor. I wish that were the end of it but next will be integrating the 129 wiring to the 107 control system.

t walgamuth · #29 03-08-2020, 11:42 PM

Very cool!

Roncallo · #30 03-15-2020, 06:44 PM

In tubing hell, but I think I found the path out. I thought I had everything figured out but then I realized the tubes would have to be crimped onto the tubes before brazing them in place. I might be able to do that if I keep a wet rag around the breadlock fitting when I braze but I decided not to risk it and design for at least 1 removable tube. In any case I have the work around, more 3D printing to check. In the mean time I practiced making a manifold out of Aluminum. The real one will be steel.