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  #1  
Old 08-28-2011, 12:39 PM
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Death of the Ambassador

Sadly, my 300SD that I've owned for 10 years has been claimed by the rust cancer beast. My fault for neglecting a water leak for too long but the drivers side floor pan is rusted through around the perimeter in many places.

The car still runs and drives great but I'm just no longer willing to sink the time and money into the old boy required to keep it on the road. This was my first Benz and it's hard to let it go but I believe it's time to part it out.

Stinks too that I recently spent a good bit of money getting the ACC working properly. Brand new (rebuild) servo, brand new blower, new amp.............

Oh well, you W116 owners look for a parts available thread in the parts forum soon.

Some pics of the rust:







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Last edited by Ether; 09-13-2011 at 12:49 PM.
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  #2  
Old 08-28-2011, 01:15 PM
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Sorry to hear of your loss.

Thanks for posting the pictures though - it looks like a similar construction to the W123 which is good to know.
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1992 W201 190E 1.8 171,000 km - Daily driver
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Don't leave that there - I'll take it to bits!
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  #3  
Old 08-28-2011, 01:46 PM
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Angle iron around the perimeter and treated plywood for a new floor. Had a friend who refloored the whole interior of a Corvair that way.
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1977 300d 70k--sold 08
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1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
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  #4  
Old 08-28-2011, 08:00 PM
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Quote:
Originally Posted by Ether View Post

The car still runs and drives great, I recently spent a good bit of money getting the ACC working properly. Brand new (rebuild) servo, brand new blower, new amp.............
116's are best...

You can rebuild him. Better. Stronger. Faster.

Well, maybe not the last part...
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  #5  
Old 08-28-2011, 08:09 PM
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Ok, so I've had some time to examine my options and reconsider the initial death sentence for my beloved W116. I'm issuing a stay of execution for the time being while I explore some ideas I have on fixing the holes while not spending a ton of money.

I have plenty of reasons to keep it on the road. For one, it's been extremely reliable (with one notable exception) for the 10 years of my ownership. The paint is a little rough in spots and it's for sure a 20 footer but it's still a handsome car and looks sharp on the road. The interior, except for a few places on the drivers seat, is darn near immaculate (well as immaculate as 31 year old MBTex can be!) and quite simply I still love driving it.

I've bought and sold a few MB's over the past 10 years but this was my first, and I've put considerable blood, sweat and curses into it over the years so I'm just not ready to give up yet.
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Joe

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
1980 300SD - 495k miles - 'The Ambassador'
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Former Family Members
95 C280
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90 300D
87 300SDL (X2)
86 560SEL
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  #6  
Old 08-28-2011, 08:33 PM
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What was the "notable exception"?

*Takes notes*
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  #7  
Old 08-28-2011, 08:56 PM
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Originally Posted by 1980sd View Post
What was the "notable exception"?

*Takes notes*
Harmonic balancer came off as I was rolling on 75 south of Macon. Engatwork helped me out with that one.

Check those bolts!
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Joe

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1980 300SD - 495k miles - 'The Ambassador'
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

Former Family Members
95 C280
73 280SEL
90 300D
87 300SDL (X2)
86 560SEL
84 300D
80 300SD

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  #8  
Old 08-30-2011, 07:58 AM
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my 240 was about that bad, I welded over 40 patches to it If I can remember.
Heres a thread on that, don't lose hope!
http://www.peachparts.com/shopforum/showthread.php?t=275274

If you do anything immediately, reinforce that seatbelt location while you consider, especially if you continue to drive it around daily. As it stands, it will fold up and pitch forward with slightest pressure.
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Old 08-30-2011, 08:43 AM
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I went through your thread and my problem is no where near as extensive as yours. I think mine may require only 4 or 5 patches to fix it up. I plan on addressing the rust with POR15 and once that is squared away will weld in the patches.
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1980 300SD - 495k miles - 'The Ambassador'
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Former Family Members
95 C280
73 280SEL
90 300D
87 300SDL (X2)
86 560SEL
84 300D
80 300SD

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  #10  
Old 08-30-2011, 08:55 AM
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Quote:
Originally Posted by Ether View Post
I went through your thread and my problem is no where near as extensive as yours. I think mine may require only 4 or 5 patches to fix it up. I plan on addressing the rust with POR15 and once that is squared away will weld in the patches.
you should reverse that order, weld, then POR (unless you are talking about the inside of the rockers, then theres no way around that)

that POR stuff is awesome, but id be concerned about welding around it and what kind of fumes it might create!

I actually considered cutting out the entire bottom side of the rocker panel to expose the inside to the elements, then welding in a framework that could allow you to get your hands in there and do work or paint over the years but still retain the tubular structural strength. Then the idea was to make a thin plastic shield that would be removable. Never got around to it though.
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Old 09-13-2011, 01:11 PM
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I've spent the last few weeks removing what rust I could and cleaning and treating the remainder with POR-15. To repair the holes I decided to go with patching them by attaching sheet metal on top of the holes as opposed to cutting out and welding in an exact fit.

I figured this would be ok asthetically since everything will eventually covered by carpet and it would be plenty strong with a combo of sheet metal screws, POR-15 & fiberglass and spot welds. This POR-15 fiberglass combination is remarkably strong once it cures.

In my eagerness I forgot to take photos of all the stages of work but below are some of the metal prior to welds and POR-15/fiberglass application.

I'm going to cover the pan with the Peel and Stick product from Lowes before the carpet goes back in.





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Joe

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
1980 300SD - 495k miles - 'The Ambassador'
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

Former Family Members
95 C280
73 280SEL
90 300D
87 300SDL (X2)
86 560SEL
84 300D
80 300SD

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  #12  
Old 09-13-2011, 01:34 PM
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Way to go

I'm glad your keeping it on the road. I used that Peel and Seal from Lowes on my floorboards.

Now you can clean the carpets well and tidy up all those corners you couldn't get to before. Your 116 will be more awesome than before!

How bad was it pulling the interior? I've always found that keeping stuff in order while it's out of the car is the hardest part...

Keep us posted!
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  #13  
Old 09-13-2011, 02:47 PM
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Nice work, Joe!
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  #14  
Old 09-13-2011, 04:09 PM
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Glad you opted to stand and fight the tin worm.

Mine was way worse when I had the floor done (neighbour who owned a bodyshop did it cheap in off hours).

That was in 2003. The car stayed on the road until 2009.
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2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22
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  #15  
Old 09-13-2011, 04:13 PM
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Quote:
Originally Posted by dropnosky View Post
my 240 was about that bad, I welded over 40 patches to it If I can remember.
Incredible work. I see what you mean about being amazed that the doors still shut properly, given that amount of rot.

That's an inspiration for us all

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2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22
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