Finishing Samson the M120 R107 - Page 11 - PeachParts Mercedes-Benz Forum

Roncallo · #**151** 11-02-2020, 09:25 PM

Time to get back to work. Is the garage clean yet, no but the table is. I now only has parts that need to go back into Samson. Tomorrow I start designing brackets and cleaning up parts to be reinstalled.

Roncallo · #**152** 11-06-2020, 09:22 PM

Good painting weather today so I decided to touch up my interior parts. All painting is now complete except for the center console.

Roncallo · #**153** 11-10-2020, 11:50 PM

Starting to close up. I would love to put the instrument cluster on and take it for a spin. But I will wait until tomorrow and give everything a good check out. I don't want to have to take it out again. I also need to install the radio speakers, but I need to test them first to make sure I have the correct wiring going to each side.

vwnate1 · #**154** 11-11-2020, 02:03 AM

Boy o boy is this project looking good .

Roncallo · #**155** 11-13-2020, 11:13 PM

This is what happens when you try to install the heater vent cable first and then try to install the duct with it installed. The tool I made worked well to install the cable with the duct in place but still a PIA because I couldn't get both hands in place to hold the clip in place while I was installing the tool. In any case all back together. Everything seams to be working except the low oil level switch. Oil light stays on at all times. I tested the switch and it appears to be not working. That switch requires removal of the oil pan to install. Its the same switch I had out to reseal 9 month ago. AC is working real well pulled the temp right down to 34° where the compressor cut out.

Tomorrow I will install the rest of the trim around the windshield and the visors. I will take it for a spin to make sure I have the steering wheel on straight.

Still along way to go. I have to fabricate covers for under the dash and the right side kick panel. But I can drive it, at least without a passenger.

Roncallo · #**156** 11-14-2020, 10:43 AM

Back on the road

vwnate1 · #**157** 11-16-2020, 10:02 AM

Very nice to see it out and about

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Roncallo · #**158** 11-17-2020, 02:40 AM

So after getting it on the road and evaluating I found 3 things that don't work.

1) Oil level light stays on at all times. I checked the oil level and found it fine. I tested the switch and found it to be bad. That will require removal of the oil pan to replace. That will be on the back burner for some time.

2) Speedometer does not work. That was caused by me not putting in the modifications necessary to power the hall effect sensor. It would have been nice to have done that with the harness out of the car but I did it once before in the car I can do it again. That will be fixed shortly.

3) ABS is not working. Haven't got the chance to check it out yet.

vwnate1 · #**159** 11-18-2020, 09:14 AM

Is the ABS light on or other ABS failure ? .

Roncallo · #**160** 11-18-2020, 06:00 PM

ABS light is on. This might be something very simple like I never connected the 2 large wires the tie it in to the main wire harness. Other than that nothing was touched on the ABS system. I haven't looked at it yet.

Speedometer sensor is coming along. All wiring complete. Now I just have to tie the wiring back in place. One more time upside down under the dash.

Roncallo · #**161** 11-20-2020, 07:36 PM

Stole the ABS module out of Delilah, and all is well. Found a used one on E-bay for $60.00. Now I just need to work on the coverings under the dash.

Roncallo · #**162** 12-01-2020, 01:06 AM

Today my parts came in. ABS computer installed and working well. Left side of interior is completely reassembled. Its the first time the car is operational with the left side heater ducting fully in place along with the knee bolster. No more relays and fuses tie wrapped in place. For the right side I still need to fabricate a new kick plate. The flat patterns are already out for laser cutting and due in this week. That will actually be very similar to the stock 560SL kick plate except stood off 1 inch higher. Tomorrow I will take it for a test drive and make sure the steering wheel is straight. Then I can do the finale tighten of the wheel and reinstall the air bag. First mock up of the kick plate will be with steel. Followed by an aluminum final version or possibly plastic.

Roncallo · #**163** 12-22-2020, 02:25 AM

It's been a long time waiting for parts. My new foot plate came in today and it seems to fit perfectly. Now I need to add a few stiffeners to it and make a transition section that goes from the plate to the lower dash covers. I will also need to take the carpet somewhere to have it shortened. When I have the final plate made out of aluminum it looks like I can extend the bottom down another 10-15mm. But I'm confident this will be the last steel one.

Roncallo · #**164** 12-23-2020, 01:37 AM

Today I started working on the transition plate that goes from the foot plate to the under dash covers. The transition plate was planed to have three rivnuts that the foot plate would bolt to. When I got it all done and everything fit together I realized that I cant use rivnuts on the transition plate because I will never get a tool in there to install them due to the 115° bend angle. I was hoping to install the transition plate behind the foot plate so that I would have a nice bent radius for any wires in the area. But with installing the plate in front of the foot plate it really doesn't look bad as long as I keep the bend from the transition plate up high and do a good job deburring the foot plate. Of course the whole transition plate needs to needs to be remade now but most of the battle is figuring out what to do.

First and second picture show the problem. Third picture shows how the bend comes over the back of the foot plate and protects any wires from the sharp edge on the foot plate. Fourth picture shows the transition plate up front, which is now the new plan. And the 5th picture shows the exposed edge on the foot plate.

Roncallo · #**165** 12-24-2020, 02:40 AM

Fit all the interior in today. Found I needed to shave 8mm off the left side of the foot plate. It fit but it was tight so 30 seconds to shear it was worth while. On the right side I found that the fuse box cover is now covered but I can just get it off. However changing a fuse just went from sucks to really really sucks. I may make that tab hanging off the right side removable. Hopefully that will make it just really sucks instead of really really sucks. The carpet fits in reasonably well but does need to be shortened. That will be a challenge because I will need to cast new foam for under the carpet, which will be a learning experience. See picture #4.

With that done I started the making braces for the plate. Picture #5 shows a cross brace going across the bottom. That gets riveted to the footplate with 15 rivets. This part becomes a highly stressed member in the event of a crash. The top transition plate is only shown with 3 clecos in place for the moment but those will be refitted with at least 5 rivnuts for the same reason.

With that done I need to start making standoffs. Those are required to support compressive foot loads as the 4 mounting tabs are just flimsy pieces of sheet metal. I completed the lower standoff se picture #6. That will replace the plastic standoff MB used see picture #7. Tomorrow or should I say today I will see if this all can be installed then it will be time to make stand off for both sides to support those areas shown in picture #8.

Getting close but still a lot to do.

See pics 6, 7 8 in next post.