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+--- Thread: dropnosky's 1980 240D (/showthread.php?tid=1573)
dropnosky's 1980 240D - JB3 - 08-04-2010
Since ive decided to put a turbo on this car, in anticipation of getting that done, a thread for it on superturbodiesel.
So far, the only mods to the car other than extensive rust repair in this thread- http://www.superturbodiesel.com/std/emergency-rust-repairs-t-1276.html
are a W201 5-speed swap discussed in this thread- http://www.superturbodiesel.com/std/how-adapt-w201-speed-om616-om617-applications-t-965.html
It started out as a basic automatic 240 with a bad trans.
Ready to be installed are a 3.46 rear end, a bull bar, and soon the turbo setup off of one of my parts engines.
Also I am working on installing a tach, and will need a boot gauge and EGT gauge.
as it stands in its current state, looks ok from far away, but it won't win any beauty contests-
what it looked like earlier, needed new fenders and a bunch of other stuff
RE: dropnosky's 1980 240D - Captain America - 08-05-2010
(08-04-2010, 03:47 PM)dropnosky as it stands in its current state, looks ok from far away, but it won't win any beauty contests-
Will any of the cars on this forum win a contest? I sure as hell hope not!
RE: dropnosky's 1980 240D - willbhere4u - 08-05-2010
Please Take good pic's of you turbo manifolds! I'm very interested in upgrading to the om617 turbo manifolds and a newer turbo on my 240 turbo project car! I need some boost before 3500rpm
The reason I did my oil drain on the upper oil pan instead of the lower was for a straight oil drain like the factory turbo car's it's worked perfectly with no leaks! but it is nerve racking to drill through knowing if you mess up there's no going back!
I wanted it to drain above the oil level so there would be any resistance or pressure on the turbo seals!
RE: dropnosky's 1980 240D - garage - 08-05-2010
I am EXTREMELY excited for this!
PLEASE take lots of pics, i hope to be heading this route with my 240 verry soon myself.
RE: dropnosky's 1980 240D - JB3 - 08-05-2010
mine might win an award for rust.
I can't believe that once again I have found something more fun to do on this car than fix the HUGE hole in the passenger floor and put in a seat. This week, ill be coming up on 6000 miles of use with a 3 foot hole next to me. Its getting ridiculous, and before you know it, it will be cold again and i will be in trouble, plus, immediate access to the road seems to bother passengers already weirded out by sitting behind me when there are two of us.Ive got a pair of UGLY manifolds from I think a 126? The early style with the turbo, but no egr, but close to the head, like the stock 617 setup. I need to get back downstate and put together what I have.
Do you think the back pressure from doing the turbo drain in the lower pan would be a real problem? Im also a little alarmed at drilling straight down through that cast piece like Will was!
It sure would be easier just to do it in the lower pan if the outcome is generally the same. garage, I promise pics!
RE: dropnosky's 1980 240D - Captain America - 08-05-2010
(08-05-2010, 12:34 PM)dropnosky mine might win an award for rust.
^^Priceless^^
Hey, I'll ride shotgun with a fat ass smile on my face!
But you don't need brakes right... ? lol that's comedy!
RE: dropnosky's 1980 240D - JB3 - 08-05-2010
(08-05-2010, 02:50 PM)Captain America ^^Priceless^^
Hey, I'll ride shotgun with a fat ass smile on my face!
But you don't need brakes right... ? lol that's comedy!
passenger view from the back seat. For some reason, no one likes riding back there on the highway or in the rain for gods sake. I usually put down some cardboard, what more could they want?
First brick wall- Turbo exhaust manifold, the 4th/5th cylinder twin port is going to be a bear to resolve. Intake should be no problem, I can just cut the last cylinder off and weld it shut.
I guess the question is do I want to mess around with welding on the cast iron manifold? anyone have any positive first hand experience with a welded cast iron component?
RE: dropnosky's 1980 240D - Captain America - 08-05-2010
awe that is a good view!
I have seen welding on cast with no issues, not pretty, but I have not done any myself...
RE: dropnosky's 1980 240D - DeliveryValve - 08-05-2010
(08-05-2010, 03:53 PM)dropnosky ....
I guess the question is do I want to mess around with welding on the cast iron manifold? anyone have any positive first hand experience with a welded cast iron component?
I asked Rudolf_Diesel this very question a couple days ago. He told me that he braze welded an exhaust manifold before with no problems.
.
RE: dropnosky's 1980 240D - willbhere4u - 08-06-2010
I've heard if you heat it up to like 250* in an oven then weld it dose alright
RE: dropnosky's 1980 240D - Rudolf_Diesel - 08-06-2010
It should be fine to weld as long as there is not a tensile load on the object welded - then there should no issue with it lasting.
Brazing is actually stronger than the parent material. I have repaired cast iron gears by brazing new teeth and have not had an issue.
I also repaired my old Rajay turbo housing (Corvair) that was cracked. I drilled a hole on each end of the crack to stop its progression then ground out a groove in the crack and brazed it up.
You let it cool naturally and give it a few small hits with a ball peen to relieve stress as it cools.
RE: dropnosky's 1980 240D - rdirtycar - 08-07-2010
(08-05-2010, 11:01 AM)Captain America(08-04-2010, 03:47 PM)dropnosky as it stands in its current state, looks ok from far away, but it won't win any beauty contests-
Will any of the cars on this forum win a contest? I sure as hell hope not!
I have a beautiful 300D because I was lucky enough to find a friend to front me while I paid it off to them. I could have bought a really nice late model 300 for the same money but I like the older models so much that I was willing to take the criticism from EVERYBODY for refurbishing it. This car is much sturdier than any new Mercedes Benz and I rationalize it from there. It's not just the engine it's the chasis that makes the 300D what it is. It took me about a year to pay for this beauiful rust free, nice interior example I have and I don't regret a second of the money I worked hard to earn for it. I think the early 300s are an amazing alternaive to the 300's of the early 00's and should be taken seriously by anyone wanting to buy a mid-size mercedes of any late model year. I had an '01 that saved my life and after owning and maintaining an '83 300D, as far as I've seen, there is no finer automobile that has ever been made. It's about the chassis as well as the 27 year old mechanicals that show no discernable signs of wear.
RE: dropnosky's 1980 240D - JB3 - 08-08-2010
you guys have emboldened me with the exhaust manifold welding. here are some pics
The turbo exhaust and intake are off of a 116 SD I think. same as the later ones, just minus the EGR, and some heat shield provisions
the intake will work just fine cut off about here. I may cut it sort of oddly to retain the ALDA port on the end-
I was initally concerned about the exhaust proximity to the starter here-
But a turbo does fit in there, it is about 1/3 to 1/2 of an inch between the heat shield and starter solenoid. Ok? I think the rubber boot may be melted, but it may be fine. I wonder if I can reclock the starter to get the solenoid down towards the passenger side?
Since welding on the manifold seems to be possible done properly, I took one of my extra manifolds and cut it up to see. I won't be able to do it properly with my fischer price welder though, I have to find someone who will do it. Looks like it will work, but I have to grind it in further and get something in there for that final off center manifold stud.
RE: dropnosky's 1980 240D - Rudolf_Diesel - 08-08-2010
If you want to ship it to me I will weld it up for you, or if you want to use a local welder - that is cool too.
RE: dropnosky's 1980 240D - garage - 08-08-2010
Oh this is too cool!!
RE: dropnosky's 1980 240D - JB3 - 08-08-2010
(08-08-2010, 02:18 PM)Rudolf_Diesel If you want to ship it to me I will weld it up for you, or if you want to use a local welder - that is cool too.
ooooo, let me take it by my local welder and if he tells me to F off, as he has done in the past occasionally, I may take you up on that!
Heres how I cut the intake manifold. I decided that I wanted all the port connections on it including the the air filter housing brackets, so I cut it in this weird way. There is only one half moon gap on the back side that needs to be filled in with some aluminum plate, otherwise the rest can just be welded together.
and here you can see the small gap-
RE: dropnosky's 1980 240D - Rudolf_Diesel - 08-08-2010
(08-08-2010, 04:45 PM)dropnosky(08-08-2010, 02:18 PM)Rudolf_Diesel If you want to ship it to me I will weld it up for you, or if you want to use a local welder - that is cool too.
ooooo, let me take it by my local welder and if he tells me to F off, as he has done in the past occasionally, I may take you up on that!
Heres how I cut the intake manifold. I decided that I wanted all the port connections on it including the the air filter housing brackets, so I cut it in this weird way. There is only one half moon gap on the back side that needs to be filled in with some aluminum plate, otherwise the rest can just be welded together.
and here you can see the small gap-
Looks good! Just let me know...
RE: dropnosky's 1980 240D - Captain America - 08-08-2010
Wow! nice work on the cutting! The manifold especially, how you are able to keep all the ports ..... Sweet!
RE: dropnosky's 1980 240D - willbhere4u - 08-08-2010
looks good!
RE: dropnosky's 1980 240D - ForcedInduction - 08-08-2010
Looks pretty sweet. That intake is going to turn out really nice.
But you shouldn't have cut up the non-EGR manifolds, those are worth quite a bit of money. I sold two to different people in France for $140 each!
RE: dropnosky's 1980 240D - JB3 - 08-08-2010
(08-08-2010, 09:36 PM)ForcedInduction Looks pretty sweet. That intake is going to turn out really nice.
But you shouldn't have cut up the non-EGR manifolds, those are worth quite a bit of money. I sold two to different people in France for $140 each!
Well, I only cut up one so far, I see your point though. I think I wil leave the non EGR exhaust manifold alone and cut up an EGR version, the later EGR one I have has more bolt holes for heat shields anyway and is in better condition.
RE: dropnosky's 1980 240D - Biohazard - 08-09-2010
Thats coming along great! Good work on the intake! Hope the exhaust works out for you too!
RE: dropnosky's 1980 240D - Captain America - 08-09-2010
Can I buy one of the non EGR's off you?
RE: dropnosky's 1980 240D - JB3 - 08-09-2010
(08-08-2010, 05:50 PM)Rudolf_Diesel Looks good! Just let me know...
He told me to F off on the cast iron, he'll do the aluminum part though.
With that it mind, I would like to take you up on your cast iron welding offer! Can I tack everything into place here and send it to you to be properly welded? Would the tacking affect the cast material or the later weld?
Captain, sent you a PM on the exhaust manifold.
RE: dropnosky's 1980 240D - Rudolf_Diesel - 08-09-2010
(08-09-2010, 11:26 AM)dropnosky(08-08-2010, 05:50 PM)Rudolf_Diesel Looks good! Just let me know...
He told me to F off on the cast iron, he'll do the aluminum part though.
With that it mind, I would like to take you up on your cast iron welding offer! Can I tack everything into place here and send it to you to be properly welded? Would the tacking affect the cast material or the later weld?
Captain, sent you a PM on the exhaust manifold.
You don't have to tack it...unless it is overly complicated, just mark it with a sharpie on two sides to distinguish which way is up or send me a pic. It looks pretty easy, just a piece to plug the hole.
RE: dropnosky's 1980 240D - willbhere4u - 08-09-2010
Great job Dropnosky Can you make me one! That will be sexy when its done! Rudolf your a stand up guy!!!!
RE: dropnosky's 1980 240D - JB3 - 08-11-2010
got my gauges! I like isspro, especially the color coded EGT
Also, I am obsessed with attaching the EGT probe in where the EGR was cause it just seems like a tidy thing to do. How much of a EGT reading would I lose do you think putting the probe off of cylinder one like this?
(08-09-2010, 01:24 PM)willbhere4u Great job Dropnosky Can you make me one! That will be sexy when its done! Rudolf your a stand up guy!!!!
All I am doing is wielding a hack saw and angle grinder! Lets see what happens after I shamelessly beg, borrow, and steal welding services from people such as Rudolf-diesel and my local welding guy who is old and cantankerous!
RE: dropnosky's 1980 240D - DeliveryValve - 08-11-2010
(08-11-2010, 07:32 PM)dropnosky ....
Also, I am obsessed with attaching the EGT probe in where the EGR was cause it just seems like a tidy thing to do. How much of a EGT reading would I lose do you think putting the probe off of cylinder one like this?
In my opinion it would not be good to put an EGT probe there. You would want it closer to the turbo in the collector area to get a more accurate reading. That port would be good for a manifold pressure fitting.
.
RE: dropnosky's 1980 240D - willbhere4u - 08-11-2010
I would agree did you see the pics of Biohazards painted exhaust manifold it ran cooler in that area!
RE: dropnosky's 1980 240D - ForcedInduction - 08-12-2010
(08-11-2010, 07:32 PM)dropnosky How much of a EGT reading would I lose do you think putting the probe off of cylinder one like this?
None. The EGR tube isn't part of the exhaust flow, its just an 8" tube to the collection area.
RE: dropnosky's 1980 240D - JB3 - 08-27-2010
Ill put the EGT in the right place. The exhaust manifold has been mailed off and Ive got a collection of parts going.
Question- Do I really need the ALDA over the ALA thats already on there?
If so, Ive got a couple on some injection pumps here, how is it properly removed?
RE: dropnosky's 1980 240D - Rudolf_Diesel - 08-30-2010
Here is the manifold before and after - I still need to add the tab for the nut.
Before
After
The material, from what I can tell is cast iron, but it is called a Si-Mo alloyed cast iron - it is very hard and has a lower carbon content = easier to weld. Temp wise it is supposed to be able to handle 1600* F vs. regular cast which is 800*F - makes sense for a turbo application.
RE: dropnosky's 1980 240D - DeliveryValve - 08-30-2010
(08-30-2010, 12:34 PM)Rudolf_Diesel ...
The material, from what I can tell is cast iron, but it is called a Si-Mo alloyed cast iron - it is very hard and has a lower carbon content = easier to weld. Temp wise it is supposed to be able to handle 1600* F vs. regular cast which is 800*F - makes sense for a turbo application.
Nice job! Interesting information you've provided. Now I am curious as to what material that N/A manifold is made of and if it would hold on that specific application?
.
RE: dropnosky's 1980 240D - Captain America - 08-30-2010
Looks Good!
RE: dropnosky's 1980 240D - willbhere4u - 08-30-2010
That looks great! What did you use to weld it! I'm assuming my crappy mig couldn't pull that off
RE: dropnosky's 1980 240D - Rudolf_Diesel - 08-30-2010
(08-30-2010, 02:42 PM)willbhere4u That looks great! What did you use to weld it! I'm assuming my crappy mig couldn't pull that off
I used a TIG welder on AC for cleaning purposes, like welding aluminum, and a silicone bronze welding rod.
RE: dropnosky's 1980 240D - willbhere4u - 08-30-2010
When things slow down I need to make one and get another used k26 at the yard's and upgrade my 240d turbo project car!!!! I think I have 1 or 2 turbo manifolds laying around
That looks sweet! great job Rudolf!!!!
RE: dropnosky's 1980 240D - JB3 - 08-30-2010
(08-30-2010, 12:34 PM)Rudolf_Diesel Here is the manifold before and after - I still need to add the tab for the nut.
Uhh, WOW. That is very impressive, thanks!
On the tab for the nut, I had not fully resolved that, since the hole was not on the same plane as the other holes, it was lower. I was going to make some kind of external clamp and file a notch that it would grab. How are you deciding where you are putting the tab? Should I send my NA manifold out to you as well before you do that, or do you have something there?
The reason I say that is that the piece actually slightly covered the hole when I sent it out, even before the extra piece welding on, the second hole was in a very awkward place. I was going to make a very oddball looking thing with a little grinding of the mainfold mating surface, almost like a off center C clamp
RE: dropnosky's 1980 240D - Rudolf_Diesel - 08-30-2010
(08-30-2010, 05:32 PM)dropnosky(08-30-2010, 12:34 PM)Rudolf_Diesel Here is the manifold before and after - I still need to add the tab for the nut.
Uhh, WOW. That is very impressive, thanks!
On the tab for the nut, I had not fully resolved that, since the hole was not on the same plane as the other holes, it was lower. I was going to make some kind of external clamp and file a notch that it would grab. How are you deciding where you are putting the tab? Should I send my NA manifold out to you as well before you do that, or do you have something there?
The reason I say that is that the piece actually slightly covered the hole when I sent it out, even before the extra piece welding on, the second hole was in a very awkward place. I was going to make a very oddball looking thing with a little grinding of the mainfold mating surface, almost like a off center C clamp
Is that why you had that indentation on the end? I thought you got a little to eager with the grinder
I was going to weld on a very thick type of washer or short tube that would fit over the stud.
Do you think I can use a 617.xxx head to do the mock up? If you want to send the manifold that is fine, might work out better. I can always grind off the piece I added and make an insert for the hole and weld it that way...no big deal. I would rather do it so all you have to do is bolt it up and go.
RE: dropnosky's 1980 240D - JB3 - 08-30-2010
I will mail you the 616 mainfold. (I should have done that in the first place. sorry
)That last hole does not match between the 616 and the 617, its almost like an afterthought and in a random place low.
RE: dropnosky's 1980 240D - garage - 08-30-2010
Wow rudolf, thats a killer job on the welding once again. Look very nice!
(08-30-2010, 08:45 PM)dropnosky I will mail you the 616 mainfold. (I should have done that in the first place. sorry
That last hole does not match between the 616 and the 617, its almost like an afterthought and in a random place low.
I will volunter my 616 and NA intake for mockup if need be, so that way you dont have to mail out another piece.
Its up to rudolf i guess
RE: dropnosky's 1980 240D - Rudolf_Diesel - 08-30-2010
(08-30-2010, 09:48 PM)garage Wow rudolf, thats a killer job on the welding once again. Look very nice!
(08-30-2010, 08:45 PM)dropnosky I will mail you the 616 mainfold. (I should have done that in the first place. sorry
That last hole does not match between the 616 and the 617, its almost like an afterthought and in a random place low.
I will volunter my 616 and NA intake for mockup if need be, so that way you dont have to mail out another piece.
Its up to rudolf i guess
Thank you, btw you do have a lead foot
, you left me behind the other night on the 91If anything we could use your engine for the mock up or I could look for a junk 240 head as there may be a market for custom manifolds and that would justify the purchase???
RE: dropnosky's 1980 240D - garage - 08-30-2010
(08-30-2010, 10:10 PM)Rudolf_Diesel(08-30-2010, 09:48 PM)garage Wow rudolf, thats a killer job on the welding once again. Look very nice!
(08-30-2010, 08:45 PM)dropnosky I will mail you the 616 mainfold. (I should have done that in the first place. sorry
That last hole does not match between the 616 and the 617, its almost like an afterthought and in a random place low.
I will volunter my 616 and NA intake for mockup if need be, so that way you dont have to mail out another piece.
Its up to rudolf i guess
Thank you, btw you do have a lead foot
If anything we could use your engine for the mock up or I could look for a junk 240 head as there may be a market for custom manifolds and that would justify the purchase???
Ha yeah, i try to keep the pedal half way to the metal on the city streets, but when i get on the fwy i can stand sitting behind cars i needa go go go, it just feels right in the ol' Benz..unfortunetly my turn signals arnt working..and i hate driving without them.
Im totally willing to volunteer my engine..as long as i have her for work the next day ha.
Im looking for a 616 head myself right now so i could port it out
When i get my turbo setup for the 616 i would loooovvvveeee to get some custom manifolds for the intake and exhaust.
RE: dropnosky's 1980 240D - Captain America - 08-30-2010
(08-30-2010, 10:10 PM)Rudolf_Diesel(08-30-2010, 09:48 PM)garage Wow rudolf, thats a killer job on the welding once again. Look very nice!
(08-30-2010, 08:45 PM)dropnosky I will mail you the 616 mainfold. (I should have done that in the first place. sorry
That last hole does not match between the 616 and the 617, its almost like an afterthought and in a random place low.
I will volunter my 616 and NA intake for mockup if need be, so that way you dont have to mail out another piece.
Its up to rudolf i guess
Thank you, btw you do have a lead foot
If anything we could use your engine for the mock up or I could look for a junk 240 head as there may be a market for custom manifolds and that would justify the purchase???
That Guy smoked the OMG617 uber diesel to !?!? lmfao! Tell me how he does it please. haha I know you coulda kept up with him if you wanted, but he flys huh?
RE: dropnosky's 1980 240D - garage - 08-30-2010
(08-30-2010, 11:08 PM)Captain America(08-30-2010, 10:10 PM)Rudolf_Diesel(08-30-2010, 09:48 PM)garage Wow rudolf, thats a killer job on the welding once again. Look very nice!
(08-30-2010, 08:45 PM)dropnosky I will mail you the 616 mainfold. (I should have done that in the first place. sorry
That last hole does not match between the 616 and the 617, its almost like an afterthought and in a random place low.
I will volunter my 616 and NA intake for mockup if need be, so that way you dont have to mail out another piece.
Its up to rudolf i guess
Thank you, btw you do have a lead foot
If anything we could use your engine for the mock up or I could look for a junk 240 head as there may be a market for custom manifolds and that would justify the purchase???
That Guy smoked the OMG617 uber diesel to !?!? lmfao! Tell me how he does it please. haha I know you coulda kept up with him if you wanted, but he flys huh?
NOOOOO WAYYYY did i smoke the tan sedan with the OMG617!
I was hopeing he would show me what was up and smoke out the whole freeway..maybe next time
Rudolf coulda flown past me like a rocket if he wanted! ha
RE: dropnosky's 1980 240D - Captain America - 08-30-2010
You forgot about the sexy brown interior (palomino?)!
RE: dropnosky's 1980 240D - garage - 08-30-2010
(08-30-2010, 11:16 PM)Captain America You forgot about the sexy brown interior (palomino?)!
I actually think palamino is the lighter color..i could be wrong though.
That interior was darn good looking, that my new favorite color interior wise.
Very elegant and classy..like a Benz should be.
What was Mercedes thinking putting a blue interior in these things?
That brown/choclate/coffee color and black are where it i at!
RE: dropnosky's 1980 240D - Captain America - 08-31-2010
(08-30-2010, 11:55 PM)garage(08-30-2010, 11:16 PM)Captain America You forgot about the sexy brown interior (palomino?)!
I actually think palamino is the lighter color..i could be wrong though.
That interior was darn good looking, that my new favorite color interior wise.
Very elegant and classy..like a Benz should be.
What was Mercedes thinking putting a blue interior in these things?
That brown/choclate/coffee color and black are where it i at!
agreed . We need to stop hijacking this thread
Sorry Drop!
RE: dropnosky's 1980 240D - Rudolf_Diesel - 08-31-2010
I was taking it easy as it was late and I had a few beers and I was babying the engine - no alternator. I usually drive it like I stole it
RE: dropnosky's 1980 240D - Captain America - 08-31-2010
(08-31-2010, 12:01 AM)Rudolf_Diesel I was taking it easy as it was late and I had a few beers and I was babying the engine - no alternator. I usually drive it like I stole it
excuses excuses lol