stan's 240D - Printable Version

stan's 240D - Printable Version

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+--- Thread: stan's 240D (/showthread.php?tid=2301)

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RE: stan's 240D - winmutt - 03-04-2011

Anyone know any box stores I can get this finesse from?

RE: stan's 240D - stan - 03-04-2011

looks like i won't be doing the big brakes for now. turns out those gen 2 calipers require 15" wheels for clearance. not feeling like going and hunting down gen 1s OR buying 15" wheels and tires. calipers are in the FS section now if someone wants them, otherwise they will just sit until i decide to get bigger wheels.

on the agenda for today - going to get the stuff to do rust removing using electrolysis. the references i'm using are http://antique-engines.com/electrol.asp and http://www.rowand.net/Shop/Tools/Electrolysis.htm

i'll post photos and everything when its running.

also need to track down the throttle rod, looks like that's the only part of the linkage i'm missing. the piece going from the pivot block on the firewall to the linkage ass'y on the valve cover.

i started writing a list of all the crap i probably should do before putting this thing on the road, and it's long! :O
-new gaskets (have a full set, thanks garage!)
-new fluids (have those on hand, will use zerex G05 for coolant)
-new belts (need to buy)
-new hoses (need to buy)
-new filters (have some, need to buy others)
-new motor mounts (need to buy)
-new headlights (7" H4s, 5 3/4" H1/H3s, need to buy)
-add wiring and relays for new headlights (have wires and oem plugs, need to make harnesses)
-pop test / shim injectors (need to borrow or build pop tester, find shims somewhere)
-valve adjustment (need to borrow or make valve adjust wrenches, buy feeler gauges)
-IP adjustment (maybe talk capt america into supervising that one...)
-citrus flush (probably do this when engine is in car and running)
-brake flush (not sure if necessary...)
-recharge A/C (could skip this)
-new tires (probably VW bus type - hankook ra08 185/82R14)
-strip/recoat aluminum wheels (paint? powder? dunno)
-finish buffing car (half is done, half needs to be done still)
-repair the tear in driver's seat, and crack in passenger seat
-track down an oem toolkit and jack for the trunk

i'm reeealllyyy crossing my fingers that the clutch on this thing is still good. won't know until i lift the engine+trans out and take a look. if the clutch is trashed that will be a bummer because they aren't cheap. probably should replace if in doubt, as there won't be an easier time than when everything is out of the car.

all this stuff has to be done by the 31st, no pressure! i feel like i'm on one of those tv shows where they have 10 days to rebuild a whole car.

RE: stan's 240D - stan - 03-04-2011

(03-04-2011, 09:59 AM)winmutt Anyone know any box stores I can get this finesse from?

no idea, i got it from a small independent auto body / paint supply shop near my house. you can order it on amazon.com though.

RE: stan's 240D - yankneck696 - 03-04-2011

It's a 3M product. Might get it at boating supply stores, too. Best bet is what Stan said. It's NOT cheap at all. Then again, I buy it by the gallon.

Ed

RE: stan's 240D - stan - 03-04-2011

(03-04-2011, 05:37 PM)yankneck696 It's a 3M product. Might get it at boating supply stores, too. Best bet is what Stan said. It's NOT cheap at all. Then again, I buy it by the gallon.

Ed

the 16oz bottle is not bad though for $15. i did half my 240d and all but the roof of my friend's durango with that bottle. you should be able to do one W123 exterior as long as you're not glopping it all over the place.

RE: stan's 240D - stan - 03-04-2011

this is my happy place

[Image: IMG_20110304_192826.jpg]

RE: stan's 240D - stan - 03-06-2011

just got home from wilmington ecology. got a pair of H3 bosch foglights in good condition, the whole throttle linkage for my setup, pair of tail bulb holders, and a like-new stock jack!

there were 3 centras in great condition on a w126, and i was SUPER tempted but my budget won't allow Sad

someone should go get those things!

RE: stan's 240D - 300SD_KY - 03-06-2011

http://www.thetruthaboutcars.com/2011/03/birth-of-the-cool-miles-davis-and-his-mercedes-190sl/

good call on the blue.

miles davis would approve.

RE: stan's 240D - Captain America - 03-07-2011

centras? what are those?

RE: stan's 240D - stan - 03-08-2011

tested out silver wheel paint to see how it looks. these are the aluminum alloys - super light compared to bundts. not going to bother tracking down hubcaps because i think i like this look more anyway. masking job was sloppy because these tires are going in the trash once the car can be driven to a tire shop.

[Image: IMG_20110308_173503.jpg]

RE: stan's 240D - mike-81-240d - 03-09-2011

Those wheels look tasty.

RE: stan's 240D - stan - 03-11-2011

did another wheel today. really stoked, i think they really help the look.

[Image: IMG_20110310_210154.jpg]

RE: stan's 240D - JB3 - 03-11-2011

that looks good, nothing like clean and functional. Now that I see how good that looks on there, I might try it with my winter tires for my 300D, which are a suitty oxidized black

Are you going to build another super rack for this?

RE: stan's 240D - stan - 03-14-2011

no super rack, just going for a nice clean restored look for now.

RE: stan's 240D - winmutt - 03-14-2011

They are black because they are supposed to have hubcaps!

RE: stan's 240D - garage - 03-14-2011

I wouldnt know FOR SURE, but i would BET that the clutch is good. The PO said it was driving perfectly before his wife ran it outa oil.

RE: stan's 240D - stan - 03-17-2011

YAY old engine and tranny are out.

need to get a replacement clutch slave line (firewall to tranny), no luck finding one online so far.

next order of business will be moving a couple items from the old engine to the new (alternator mounting bracket, and a few small bits). also need to track down some clutch plate bolts - someone nearly rounded them out at some point and it was dicey getting them out. wouldn't want to reinstall those ones again.

pictures when i dig out my droid.

RE: stan's 240D - stan - 03-18-2011

took the snipped clutch line to mesa hose in costa mesa, got a new piece braised up while i waited, and it was fairly cheap too. the added benefit is that segment is now removable independent of hte hardlines, and is stainless steel braided instead of just rubber.

working on cleaning up the tranny - it had 10mm thick of grease in places :O

RE: stan's 240D - stan - 03-20-2011

oh god damn it. it has just come to my attention that i should have marked the positions of my driveshaft halves before i pulled the front half out.

is there any hope for getting it lined back up right? :-(

RE: stan's 240D - George3soccer - 03-20-2011

yes there should be a white mark on one side of the half, and there should be two other marks where the one side of the half should meet between the two marks. Something like this.

=-

Well thats for a w201 w124 chassis, should be the same for yours.

RE: stan's 240D - stan - 03-21-2011

empty!

[Image: IMG_20110321_132940.jpg]

my mother is understandably anxious for me to finish the engine swap so she can have some garage space again Tongue

RE: stan's 240D - winmutt - 03-21-2011

Tooth brush and degreaser time. Seriously, its a once in a lifetime (hopefully) opportunity.

RE: stan's 240D - stan - 03-21-2011

(03-21-2011, 04:41 PM)winmutt Tooth brush and degreaser time. Seriously, its a once in a lifetime (hopefully) opportunity.

how do you think the firewall and fenders are so clean? i'm workin on it!

RE: stan's 240D - stan - 03-24-2011

a week from today the car is getting kicked out of my garage, so it's now crunch time!

2 days of PB blaster and a man-yard of torque finally got the flywheel bolts off. cleaning all the residue off it before putting it onto the new engine.

TO DO (there is more but this is what i can think of off the top of my head):

-assemble motor mounts into one good pair (from two partial sets)
-reassemble clutch ass'y
-mate up engine and transmission
-detach front half of driveshaft from transmission, index to rear half
-move IP/filter fuel lines (w/ banjo fittings) from old engine to new
-move primer pump ass'y from old engine to new
-remove and inspect vacuum pumps from both engines, install best one on new engine
-install new power steering pump and lines
-move oil cooler lines from old engine to new
-reinstall water pump housing/ass'y and thermostat w/ new gaskets
-reinstall repaired clutch line
-put new engine and transmission into chassis
-reattach speedometer cable
-reattach heater hoses
-reattach electrical connections
-reinstall refurbished headlight ass'ys
-replace exhaust manifold and gasket
-valve adjustment
-remove and replace exhaust hanger rubber doughnuts
-reinstall painted valve cover with new gasket
-install new throttle linkage ass'y from firewall to IP
-drain transmission fluid, replace with mobil 1 synthetic ATF 2qts
-flush cooling system and fill with zerex G05 12qts
-install new oil filter and 8qts 15w40 oil
-paint drivers' side wheels
-mask and buff drivers' side half of car
-repair door seal cracks with black RTV

later on:
-replace speakers
-replace stereo head unit ass'y
-source R12 refrigerant for A/C recharge
-repair driver's seat bolster tear
-replace all emblems front/rear

RE: stan's 240D - Captain America - 03-24-2011

You and your lists. I'm not even reading that Big Grin

RE: stan's 240D - stan - 03-25-2011

done tonight: flywheel swapped, clutch ass'y mounted, injector hardlines installed, some of IP/lift pump/filter lines swapped.

next up will be mounting accessories (alternator, water pump) tomorrow.

forgot this but i need to source return lines asap. no idea where the cheapest place will be though...

RE: stan's 240D - Captain America - 03-25-2011

PartsGeek.com It's one day shipping

RE: stan's 240D - mike-81-240d - 03-25-2011

Napa has em too.

RE: stan's 240D - stan - 03-25-2011

i ended up saying fuckit and ordered 5 meters. i had credit with amazon to cover it, plus i have prime, so it was $42 for the 5 meters with next-day shipping. i guess if anyone needs return lines in teh future, i will be your man Tongue

going to get cracking on that big list now.

RE: stan's 240D - Captain America - 03-25-2011

Wow 5 meter? How many motors you re lining?

Use some for vacuum lines!

RE: stan's 240D - stan - 03-25-2011

god damn it. broke one of the vacuum pump mounting bolts.

done so far: motor mounts, starter, water pump, alternator, and manifolds all mounted.

to do today still: mount vacuum pump, replace remaining IP plastic lines, find the thermostat housing bolts so i can mount that, mate engine and transmission.

RE: stan's 240D - stan - 03-25-2011

Vacuum pump mounted, lift pump ass'y replaced (w/ primer), motor mounts swapped, fuel lines and filters replaced, oil filter replaced, oil cooler lines replaced, tstat housing mounted, fan mounted, belts replaced.

Keeping track for my sake lol

RE: stan's 240D - garage - 03-25-2011

Lotsa fun stuff Big Grin

This is all good info, the lists and whatnot, to be able to come look at for later use.
Cant wait to see her when shes all done!

RE: stan's 240D - stan - 03-25-2011

(03-25-2011, 10:26 PM)garage Lotsa fun stuff

This is all good info, the lists and whatnot, to be able to come look at for later use.
Cant wait to see her when shes all done!

yeah man i figure its good for me to keep track right now, and it will be nice to have tabulated for later on.

i know you had mixed feelings on selling the body, but let me tell you i've probably got close to 100 hours into the thing right now, and at least another 20 before its driving. it's gonna look nice, but it definitely is taking shitloads of time, so don't feel bad lol.

money so far on the project:

$440 - engine from craigslist
$40 - fuel to pick engine up
$250 - rolling chassis from garage
$65 - trailer rental to get car (uhaul)
$75 - fuel to tow car home
$30 - clutch line repair (mesa hose, costa mesa)
$50 - gloves, cleaning chems, paints
$30 - 15w40 oil
$45 - zerex coolant
$40 - 5 meters of return lines (amazon)
$110 - filters, belts, small tools (amazon)
$50 - assorted small parts (junkyard - ecology)
$75 - paint restoration supplies (paint depo - lake forest)
$45 - 2x cherry picker rental (rent one - costa mesa)
--------------------------
$1345 - estimated current running total (rough)

near future:
$180 - tires
$100? - R12 refrigerant
--------------
$1625 - estimated final (rough)

calling it a night, here's some photos

[Image: IMG_20110325_154102.jpg]

RE: stan's 240D - garage - 03-26-2011

Ask dieselboy to send you the intake manifold!!

RE: stan's 240D - Captain America - 03-26-2011

Yeah that mani is welded up tits!

RE: stan's 240D - garage - 03-26-2011

See post #4 stan!
http://www.superturbodiesel.com/std/thread-240dog-rally-car

RE: stan's 240D - stan - 03-26-2011

GREAT SUCCESS! here are some photos

i was able to get a friend to come help line everything up

[Image: IMG_20110326_114808.jpg]

RE: stan's 240D - garage - 03-26-2011

SWEEEET Cool

RE: stan's 240D - stan - 03-26-2011

things to be done today/tomorrow:

-reinstall front half of axle (had to remove it to get engine and tranny in
-hook up shifter linkages
-install radiator and hoses
-hook up heater hoses
-hook up electrical connections
-hook up power steering lines
-hook up vacuum lines
-hook up fuel lines
-hook up speedo cable
-hook up clutch line
-install oil cooler and hook up oil cooler lines

i also need to figure out how to splice the oil pressure gauge line. i have the one going from teh gauge through the firewall, and the one coming from my oil filter housing....any thoughts on how to mate those two ends properly? its a hard plastic line so i am not sure....

one more picture - i'm REALLY stoked on how well the paint is buffing out. once the rubber is cleaned up all nice and black, and the trim chrome gets polished this thing is gonna be SOOOOOOOOOOOOOOOO clean. still deciding what to do with the lugs and dust caps on teh wheels, maybe gloss black?

[Image: IMG_20110326_124613.jpg]

RE: stan's 240D - Imaginos - 03-26-2011

Very nice work. I love the painterd wheels too.

RE: stan's 240D - willbhere4u - 03-26-2011

I think the oil line is supposed to be one piece from the gauge to the filter housing and I think they are still available new!

better safe than sorry if it's broken it will loose all of the engine oil!

RE: stan's 240D - stan - 03-26-2011

bad news about the oil line....

more photos, starting to piece together the little things

[Image: IMG_20110326_185256.jpg]

RE: stan's 240D - 300D50 - 03-26-2011

The fitttings are press-on, just replace the tubing. Wink

RE: stan's 240D - stan - 03-26-2011

i must say, replacing the headlights has been the most tedious job on this project so far. and thats saying something when you consider the hours upon hours i spent degreasing parts with a toothbrush.

cool trick i figured out for setting the tension springs on the headlights is to loop string on the spring and use that to pull it through the back plate and hook onto the little pin.

definitely makes me want to put euro headlights in when i have the money for it. for now, the fogs are now 100 watt, and i just put the old sealed beams in for the hi/low beams. polished the chrome and the doors, washed everything real good. will have to diddle with it some more to get the lights all adjusted properly. not sure if the 100W fogs will be too much for the fuses, i have sets of oem relays and plugs if it ends up being necessary.

RE: stan's 240D - garage - 03-26-2011

Euro lights and we'll have to source some euro bumpers....mmmmm

RE: stan's 240D - stan - 03-26-2011

and a new hood ornament. we accidentally snapped mine off when it bumped the garage door this morning Sad

RE: stan's 240D - garage - 03-27-2011

Look at all that veg paraphernalia Wink

RE: stan's 240D - stan - 03-27-2011

battery is charging up before a test run of the engine! got the headlights mounted and they're working now.

[Image: IMG_20110327_112826.jpg]

RE: stan's 240D - stan - 03-27-2011

to do today:

install driveshaft
hook up power steering lines
hook up clutch lines
hook up speedo cable
reinstall shifter linkages
ground strap for engine
rubber exhaust hangers - install
attach exhaust to exhaust manifold
bleed clutch lines and cylinders