Finishing Samson the M120 R107 - PeachParts Mercedes-Benz Forum

Roncallo · #1 09-24-2019, 10:10 PM

Many people hear are aware of the M120 powered R107. If not the thread is here:

M120 into 560SL (With Pictures!)

But what has been going on since. They say these projects are never done and yes there is some truth to that.

Once I got the engine installed and successfully running, I kind of took a breather to enjoy the car for a bit. Plus I moved from CT to NC and had to build a new shop. So about 2 years ago I decided to perfect the bread.

While Samson ran strong and reliable and had driven from main to FL and back along with several other long distance excursions, there was still a bit of fit and finishing to do.

The following was still left has been being actively addressed over the past 2 or 3 years.

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

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

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

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

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

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

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

7) Evaporation emission system need to be completed.

8) 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.

9) A cold air intake would be welcome.

10) Make more room for M120 / M113 twin cats, see: Dimensions Needed for After Market Cats

With items 2 thorough 9 complete. The car will be completely disassembled and sent out for paint. While out for paint Samson's modified subframe will be fit into a parts car I have and the M113 engine will be test fit. Any adjustments required will be designed into a new subframe designed to fit both the M120 and the M113. I may at this time also apply modifications to the frame for more cat room. That is a tough one as it requires cutting a main structural beam (the tunnel) of the frame and suitably welding it back together. That will require me to break out the aerospace structures books which have not been cracked for 30 years.

When Samson comes back from paint, the engine and components will be cleaned and reinstalled. Samson will be an M120 powered R107 as if it left the factory that way.

Tooling has already been built to do any machining required on the subframe mods in preparation for project.

First picture shows the subframe holding fixture with a front subframe on the mill. Other pictures show additional parts that were rebuilt or made ready in for the project.

Along with replacing the larger 129 differential with an overhauled 107 diff, the shortened axels from the 129 had to be replaced with stock 107 axles witch are shown ready for shipment to the rebuilder. The shortened drive shaft gets replaced with a rebuilt stock 107 shaft. All that work got me back my limited slip diff and ABS.

The last two pictures show the cutting tool I made and how its installed. It is a cut off wheel on linear bearings. The last picture show how it is attached to the car to make a nice square cut on the lower edge of the tunnel.

Roncallo · #2 09-29-2019, 08:58 PM

Outer axles have been sent out for overhaul to RVC performance. I have new inner CV to go on but while I'm waiting I decided to over haul the old inner CVs myself. It turns out they are in very good shape. I only found 1 minor spal on one of the center spiders. I will put it together and use it last if need be.

Roncallo · #3 11-10-2019, 09:34 AM

I finished reassembling my axles.

I installed the axles with the required tone wheels for the 2.82 LSD differential.

I installed the 2.82 LSD differential

I installed my newest speedometer sensor after fabbing a new bracket for it.

As of a single 3:00 AM drive around the block this morning all was working well.

Today I will be installing the hardtop as required for drag racing. I t will also be a good opportunity for checking for any sign of differential whine.

Note the standard PEX tubing crimp pliers available from Home Depot. are perfect for crimping the MB axle boot clamps.

Also note that having a spare set of differential output flanges comes in really handy for packing the inner CV joints.

vwnate1 · #4 11-17-2019, 10:48 AM

Looking good ! .

What typ of grease did you use on the CV joints ? .

Roncallo · #5 11-27-2019, 07:11 AM

Quote:

Originally Posted by vwnate1

Looking good ! .

What typ of grease did you use on the CV joints ? .

I used Redline CV-2 grease.

t walgamuth · #6 11-27-2019, 11:14 AM

Wow! What a project! I am impressed with all your fine work. The details will kill you on a job like this. It's hard enough doing all the little things on my uber simple Studebaker/mb diesel truck. Other people look at it and see a finished truck. I look at it and see my punch list to complete.

Roncallo · #7 12-15-2019, 12:27 PM

OK Speedometer is done and working perfectly along with the 2.82 LSD differential. Still need to re calibrate the speedo for the new gears but let me see if I like the new gears first.

So now its on to AC. I purchased a condenser kit and did a rough model of it. Now its time to start making brackets for installation.

Preliminary models indicate I have a solution. May have to modify the front cross bracing. But so far positive clearance.

Roncallo · #8 12-15-2019, 12:28 PM

Quote:

Originally Posted by t walgamuth

Wow! What a project! I am impressed with all your fine work. The details will kill you on a job like this. It's hard enough doing all the little things on my uber simple Studebaker/mb diesel truck. Other people look at it and see a finished truck. I look at it and see my punch list to complete.

Thanks T

Roncallo · #9 01-24-2020, 01:52 PM

Modeling of the condenser mounting details is complete. Now just waiting for some parts to come in from McMaster and Mercedes. While I'm waiting Its time to be looking into pluming especially in the area around the compressor manifold. This manifold will need to be hand made.

vwnate1 · #10 01-24-2020, 10:11 PM

To watch a Professional working

.

I forgot where I bought my CV boot clamp pliers, might have been Harbor Fright, maybe on Amazon ~ I know there were many choices and I'm on a tight, fixed budget do I gambled on the cheap ones and they seem to work well .

? Any noise or vibration from that spalled CV joint ? .

I re used one like that and forgot which axle it was on so I have no idea if I remembered to install it for reverse primary rotation....

Roncallo · #11 01-25-2020, 12:18 AM

Today was spent evaluating and designing a new AC compressor manifold to allow lines to be routed with the V12 installed. The pictures show a design that mimics the original oem used on the SL600 129 followed by a modified design that I'm hoping will work in the 107. Unfortunately making this requires a CNC milling machine which I don't have, but I hope to get access to one soon.

Roncallo · #12 01-25-2020, 12:21 AM

Quote:

Originally Posted by vwnate1

To watch a Professional working

.

I forgot where I bought my CV boot clamp pliers, might have been Harbor Fright, maybe on Amazon ~ I know there were many choices and I'm on a tight, fixed budget do I gambled on the cheap ones and they seem to work well .

? Any noise or vibration from that spalled CV joint ? .

I re used one like that and forgot which axle it was on so I have no idea if I remembered to install it for reverse primary rotation....

I never installed the spalled CV joint. Just took it apart and cleaned it and put it away as a spare.

As far as the pliers I just did a pex plumbing job on my hose and happened to have them. They looked like they would work and they worked like they were designed for the job.

Roncallo · #13 01-26-2020, 12:09 AM

The compressor line set will be fun. I will need to figure out how to make this or find someone else that can. I don't even know if this will fit yet. Its my first guess. I will need to remove the subframe to remove the compressor to try some mockup units.

PhillipinGA · #14 01-26-2020, 11:29 AM

Looked at your other thread when I saw this one, amazing craftsmanship and much respect for your surgical clean work areas. Mine are like that coin game at a carnival, just waiting on it all to fall down.

Roncallo · #15 02-08-2020, 02:04 AM

I finally got some time to work on my project. I finished up the condenser mounting. It also appears that I have 3/16" of clearance on the fan. Its closer than I would like but I think it will be fine. I still need to check if the lower condenser mounts will fit on Samson. If not I may have to offset them further forward, which may make the fan hit. I did have to modify the cross bracing slightly because the lower center bolt would have hit the fan. It was an easy solution, just bend the lower tabs forward, drill a hole and nut and bolt it. The fan is just laying in place now so the rest of the weekend will be fabrication of the fan mounts. But so far I am very pleased, hose routing seams doable and I have room for the Receiver dryer.