Finishing Samson the M120 R107 - Page 7 - PeachParts Mercedes-Benz Forum

vwnate1 · #91 06-24-2020, 03:42 PM

Don't drill the hole ! .

Use a properly sized chassis punch .

I'm ever so grateful to the old Mechanic who taught me this in 1971....

Roncallo · #92 06-26-2020, 01:14 AM

Quote:

Originally Posted by vwnate1

Don't drill the hole ! .

Use a properly sized chassis punch .

I'm ever so grateful to the old Mechanic who taught me this in 1971....

They are nice but $111.00 for 1 size. I used a hole saw. It came out fine. But I got the new 3 qt washer bottle and I may have messed up the hole on the bottom got the level sensor. I inadvertently hogged the hole out too big and it has a slight leak. Hopefully silicone will fix it. Otherwise there is a 28.3mm punch available. I really need 28mm but I think that will be close enough.

vwnate1 · #93 06-26-2020, 01:35 AM

You need to look harder for them .

The Chinese ones work fine ~ it's not like you're a Dealer P.D.I. man using it daily for years....

URO Parts Support · #94 06-26-2020, 12:10 PM

Quote:

Originally Posted by vwnate1

Don't drill the hole ! Use a properly sized chassis punch. I'm ever so grateful to the old Mechanic who taught me this in 1971....

Whoa, those are awesome! Thanks for the tip.

vwnate1 · #95 06-26-2020, 12:36 PM

.
......Of this site is to help others and exchange ideas, right ? .

I'm an old Journeyman mechanic who's retired now yet I've received far more help and good tips than I could ever repay here .

Roncallo · #96 06-27-2020, 12:44 AM

Found all the parts, The new tank came in. Completed all the electrical and plumbing. Now just waiting for the paint to dry on the last bracket I had to make. One problem I had was making the hole for the level sensor too big. It has a slight leak but hopefully some silicon with fix it. Tomorrow I will try it out.

Roncallo · #97 06-27-2020, 09:13 AM

Quote:

Originally Posted by vwnate1

Don't drill the hole ! .

Use a properly sized chassis punch .

I'm ever so grateful to the old Mechanic who taught me this in 1971....

I just ordered this set. If I have to order another reservoir I will give this a try. It should be able to punch a hole in plastic.

Thanks for the tip.

https://www.amazon.com/dp/B0817325R4/ref=sspa_dk_detail_3?psc=1&pd_rd_i=B0817325R4&pd_rd_w=RoLKJ&pf_rd_p=48d372c1-f7e1-4b8b-9d02-4bd86f5158c5&pd_rd_wg=qK3vP&pf_rd_r=K31N5DM8C0J458HG1627&pd_rd_r=d8dcb6ca-d50b-4723-91da-167b6776bd55&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUEyQjJVSTBNUEJNVDRVJmVuY3J5cHRlZElkPUEwODI5MzMwMkZUV1pWME RWMjBISyZlbmNyeXB0ZWRBZElkPUEwMDg1MDQ4MTMyUzNFODVJS1dXQSZ3aWRnZXROYW1lPXNwX2RldGFpbCZhY3Rpb249Y2xpY2 tSZWRpcmVjdCZkb05vdExvZ0NsaWNrPXRydWU=

vwnate1 · #98 06-27-2020, 12:10 PM

There you go .

In my day I only saw single sized punches, this looks handier .

If carefully used you'll get nice clean holes with even edges unlike those stepped drill bits make .

Roncallo · #99 06-27-2020, 08:49 PM

Crash and burn today with the windshield washer. I had a very slight leak yesterday at the level sensor. Put silicone on it and today it was like Niagara falls. Went to test the system to see if it at least worked. No could just be a blown fuse or the WW pump I got out of "Ebola", a car that looked like it was fished from the Marianas Trench. Then I went to open the hood and it was stuck hooked on to the cap for the WW filler. I actually checked to make sure that wouldn't happen on the other car, but different cars have different tolerances. Nothing impossible to fix but about another $100 to 200 in parts and welding and another weekend or so. The only thing I'm most concerned with is the leak, I may have to look into an alternative sensor that goes into the top if I can find one the right size that uses a small hole. The one I have now is from a 2004 Acura. It plugs in from the bottom and obviously making a clean round hole is key. I just ordered some chassis punches which should be able to make a clean hole in plastic. But for the moment this will be on the back burner until after the AC back together and the shop is returned back to some sense of normal.

Roncallo · #**100** 06-28-2020, 11:10 AM

Big success on the AC. These taken 81° F ambient 65% RH, using standard test conditions, engine at 2000RPM windows down, blower high, recirc off. Also checked evaporator temp operation. Engine at idle, blower low, windows closed recirc on. Clutch cycled off at 32°F back on at 36° F.

AC is done.

Roncallo · #**101** 06-28-2020, 05:49 PM

My chassis punches came in and they seam to work really well on the plastic bottle. Hole is clean and the perfect size. Everything fits perfectly. I'm confident this will work.

Now should I order 1 or 2 bottles. They are $26 each + $20 shipping and profit. Will it still be $20 shipping if I order 2?

I also should get a new rubber bushing. Those are $8.00 + $9.00 shipping and profit.

I will work on the electrical issues first.

Roncallo · #**102** 07-01-2020, 11:09 PM

New reservoir came in today successfully drilled it with a chassis punch. Made a nice round perfectly sized hole. No leaks at all. Monday the new pump should be in.

Roncallo · #**103** 07-02-2020, 11:26 PM

Pump came in early. All is installed and working well except I need to replace the driver side nozzles.

I had to install a smaller filler cap to clear the hood.

But now its done.

So what next?

The last system that is not working of the original 560SL is cruise control. I think I will be looking into this next. I kind of forgot about this and its not on my original list in post 1, because I don't generally use cruise control,but I came across all the wires for it when I was doing the AC. so here goes.

Roncallo · #**104** 07-03-2020, 10:36 AM

I took the time to reorganize the items in the first post. So first 7 items are now complete. Items 8 to 11 are the only things required before Samson it ready to be completely disassembled for repaint. Item 12 can be done on my parts car.

Evaporative emissions looks fairly easy as the 96 SL600 canister looks the same as the 107 canister except made of plastic.

Cruise control will require some research but looks like there is a possibility it will be easy.

Permanent wiring under the foot well and coverings. Fairly straight forward but I may have to hire a young more flexible guy to work under there.

Cold air intake I just have to get off my ass and do.

1) Badly needed real LSL differential, done see: Differential Build Tool Ideas. Done

2) Needed to get the ABS working. Done with the 126 diff installation above. Done

3) Need to get the speedometer working. Hopefully will be done in about two weeks see: Connect 722.6 Transmission to Electronic Speedometer. Done

4) Need to get the AC working. Just started looking into this. Done

5) Need to make a windshield washer reservoir. Will be looking into this when I can't work on the AC due to cash flow. Done

6) M120 Tandem pump needs to be disassembled to have the extra hydraulic rotor removed. That will allow me to get rid of a reservoir that does nothing but pump fluid around in circles. Done

7) Make more room for M120 / M113 twin cats, see: Dimensions Needed for After Market Cats. Designed but will not be installed on Samson

With that complete the car will very well refined with only minor convince issues.

8) Evaporation emission system need to be completed.

9) Connect Cruise Control

10) Finish permanent wiring and foot well covers.

11) A cold air intake would be welcome.

12) Could I build another one and could I make it fit both an M120 and an M113.

Roncallo · #**105** 08-04-2020, 11:57 PM

Unfortunately Samson has taken a turn for the worst. With everything up and running perfectly, I drove the car up to Long Island. The car performed flawlessly for the trip. AC worked very well no overheating. But a few days later I fried the main wire harness and had to have the car transported back down to NC for surgery. Fortunately at this point all damage appears to be limited to the 107 side of the wiring but it is the main wire harness and it will be a huge job to replace. The problem occurred from the circuit 15 wiring being chaffed by the passenger side kick panel. This melted the circuit 15 wire from the fuse block to the ignition switch and probably many more wires it was in contact with in the bundle.

I do pride myself with up time on this car and this is the first time in 12 years that this car will be down for an actual failure. But in reality this is my own fault in that the wiring was done in a more or less temporary fashion to get the car running. Half of that was because the wiring has never really been finalized until very recently with the installation of the AC and the windshield washer. The other half is just pure laziness.

The wiring on the car is now fully established with the exception of cruise control which should be a very minor small harness installation which will be independent of all wiring done to date.

So with that being done it is actually a pretty good time for this to happen. For one it is getting me off my ass to do a robust wiring job. For two it will give me the opportunity to remove wires from the 107 harness that are no longer used, where the tasks have been taken over by the 129 harness.

So I started this job by removing the wire harness for my 107 parts car and labeling each connector and terminal block. With that harness I will have a map of how to install it. The 107 main wire harness stretches out to over 18' long.

Before removing the wire harness from Samson I will try to start the engine by bypassing the 107 harness to check that the computers have not been effected.