US spec 123 bumper mod, removing all rubber end trim

US spec 123 bumper mod, removing all rubber end trim - Printable Version

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US spec 123 bumper mod, removing all rubber end trim - JB3 - 09-26-2013

For the last couple weeks ive been trying to resolve some of the rust issues on my DD 240 sedan. The car is not too bad, but needs floor pan repair, and fender work.

I gave the car to a trusted body guy who is working on a plan for me regarding the rubber bumper ends-

It is my opinion that all the rust that kills the front and rear fenders on 123 chassis (outside of wheel well rot) comes from the rubber bumper ends bracketry, which has a crappy finish, rusts, and transfers rust into the body.

Example-
Perfectly good fender sandwiched against a piece of rusty garbage, added bonus is the bracket also traps debris to accelerate rust-

looks ok from 20 feet-

but behind the bumper-

debris and rust against the fender-

telltale signs of damage from this situation-

The rot starts around the holes, and travels down the fender seam, and end result is the fender is in a bad way.

Here is how bad the damage actually turned out to be-

rear-

rear rubber trim bracket-

transferred rust from that piece of crap trim bracket-

fronts-

I didn't want to repair it in the same way as the stock situation, as the same sort of rust would just begin again since I use this thing year round, so my intended solution is to make each bumper, including end treatments, attach only via the 6 bolts in front and 6 in rear.

The plan is to modify the fenders and bumpers themselves, either by shaving down or moving mounts on the bumper and changing the fenders to make just the fender alone look good without the rubber crap on it.

with that in mind, I started to have the front fenders repaired, and instead of rebuilding the mount location, I requested a smooth fill that continues the lines of the fender.

Here is how that is progressing-

rust repair on driver and passenger, and stock arrangement as comparison

stock-

changed-

^^^ this required a slight change to the support structure of the fender itself, there is a bracket on the back side that has to be modified, but its a part of the fender, and was an easy cut.

Driver front primed, all the bolt holes to hold on the rubber brackets have been filled as well-

This is where im at now, the rear fenders are going to get the same treatment, but its more of just filling a number of holes instead of any shape change.
Once this is done, I can begin refitting the bumpers themselves

RE: US spec 123 bumper mod, removing all rubber end trim - DeliveryValve - 09-26-2013

Beautiful job on the welding and on the finish product.

Looking at your car, I now wonder if you can do a plastic covered bumper and how it would look like. That is using an appropriate bumper to cover up.
Now of course that will not solve your minimal attached parts to prevent rust to the sheet metal issue by adding more attachment points. Undecided

RE: US spec 123 bumper mod, removing all rubber end trim - 1911diesel - 09-28-2013

hummm, i have thought about this since i pulled the bumpers off of my 82 coupe. Looking at the bumpers off of the car, i think i want to cut them down to look like old vw bumpers, and cut the mounting brackets way down to tuck the bumper closer to the car and delete the rubber trim. ill see if i cant get some pics of the bumpers and have the woman photo shop them for me tonight so you can see what im talking about. but i think its a great idea! maybe if your idea looks better then what i had in my head i might borrow it! lol

RE: US spec 123 bumper mod, removing all rubber end trim - sassparilla_kid - 09-28-2013

I think if one were to remove the rubber end caps and weld extra material to the bumper so it wrapped around on either side that might look pretty good

RE: US spec 123 bumper mod, removing all rubber end trim - JB3 - 09-30-2013

(09-26-2013, 12:02 PM)DeliveryValve Beautiful job on the welding and on the finish product.

Looking at your car, I now wonder if you can do a plastic covered bumper and how it would look like. That is using an appropriate bumper to cover up.
Now of course that will not solve your minimal attached parts to prevent rust to the sheet metal issue by adding more attachment points.

the guy is definitely a body man of the old school. I assumed the fenders were junk and he just said "why? cheaper to save them, lets weld in some steel" then he whipped up some replacement steel patches on the ol english wheel.

you want me to drill new holes in my repaired fenders?? heresy Big Grin

(although a newer bumper skin might be interesting)

(09-28-2013, 12:58 PM)1911diesel hummm, i have thought about this since i pulled the bumpers off of my 82 coupe. Looking at the bumpers off of the car, i think i want to cut them down to look like old vw bumpers, and cut the mounting brackets way down to tuck the bumper closer to the car and delete the rubber trim. ill see if i cant get some pics of the bumpers and have the woman photo shop them for me tonight so you can see what im talking about. but i think its a great idea! maybe if your idea looks better then what i had in my head i might borrow it! lol

I haven't had as much play time with the front bumper before I handed the car over for body work, but on the rear thats definitely my goal after looking at it. One thing that struck me, is that if the US spec bumper was 2-3 inches shorter in length, the curve of the bumper actually exactly follows the curve of the body when it comes to the corner area. It would look spectacular if it was just a bit shorter. Im also sliding in the rear bumper a couple inches the same way you are thinking. I have to remake the mounts anyway as this happened as soon as I touched it-

(09-28-2013, 02:32 PM)sassparilla_kid I think if one were to remove the rubber end caps and weld extra material to the bumper so it wrapped around on either side that might look pretty good

I was thinking along these lines as well, especially for the front. The problem for me is construction of the bumper. Anyone have any ideas on the best way to remove chrome electroplating from aluminum? is this a matter where I can peel it off?

RE: US spec 123 bumper mod, removing all rubber end trim - sassparilla_kid - 09-30-2013

Chrome can be chemically removed by places that do any kind of plating I think

RE: US spec 123 bumper mod, removing all rubber end trim - Simpler=Better - 09-30-2013

http://lmgtfy.com/?q=removing+chrome+plating

You might be able to hammer it off, since the chrome is hard and the aluminum is soft. But then you will have a hammered finish bumper :p

RE: US spec 123 bumper mod, removing all rubber end trim - JB3 - 10-02-2013

^^^
the idea of dropping the bumper in a container full of soda overnight and scraping off the chrome next day is really appealing to me, gotta say.

That link doesn't specific what kind of soda in that method, but Im sure I can research the most acidic type out there. Lots of good ideas in that link

Might do a test on a small ruined chrome piece and see what happens

RE: US spec 123 bumper mod, removing all rubber end trim - Simpler=Better - 10-02-2013

I know bottom-of-the-barrel packing tape adhesive will eat it too but takes a while

RE: US spec 123 bumper mod, removing all rubber end trim - sassparilla_kid - 10-02-2013

My boss told me a story about one time his brother in law was doing some construction at a coca cola bottling plant and while they were there a container of super coke concentrate got spilled, and by the time all of the stuff was gathered to clean up the spill it had already eaten through the concrete floor

RE: US spec 123 bumper mod, removing all rubber end trim - JB3 - 10-23-2013

smoothed fenders painted and finished!

rear screw holes repaired and painted!

no side holes for rubber trim mounting in the body now, front and rear!

now to play with the bumpers

here is what the front bumper looks like stock position without rubber-

I think if I collapse the shocks, I can tuck it in far enough that it will look pretty decent. this thread has all the info I need!

http://www.superturbodiesel.com/std/Thread-DIY-W123-Bumper-tuck

Reading on here, I just have to drill through and compress them so all the fluid leaks out, then lock them in place?

RE: US spec 123 bumper mod, removing all rubber end trim - JB3 - 10-23-2013

collapsing the shocks did the trick, looks way better
still needs end treatment to look perfect, might look fine without that rubber strip though, but first to play with the rubber ends

RE: US spec 123 bumper mod, removing all rubber end trim - Simpler=Better - 10-23-2013

After seeing what happened to purplecomputer, I wouldn't collapse the shocks but maybe recess the mounts?

RE: US spec 123 bumper mod, removing all rubber end trim - JB3 - 10-23-2013

(10-23-2013, 12:23 PM)Simpler=Better After seeing what happened to purplecomputer, I wouldn't collapse the shocks but maybe recess the mounts?

his accidents are a perfect example of how useless the bumper is anyway IMO honestly, unless you hit another older benz. Most accident pictures from the front people post show the bumper slipping underneath the car in front, headlights, hood, and grill taking the hit.

plus, since this is a NA 240, im more likely to get rear ended. Big Grin

RE: US spec 123 bumper mod, removing all rubber end trim - Simpler=Better - 10-23-2013

(10-23-2013, 01:21 PM)JB3
(10-23-2013, 12:23 PM)Simpler=Better After seeing what happened to purplecomputer, I wouldn't collapse the shocks but maybe recess the mounts?

his accidents are a perfect example of how useless the bumper is anyway IMO honestly, unless you hit another older benz. Most accident pictures from the front people post show the bumper slipping underneath the car in front, headlights, hood, and grill taking the hit.

plus, since this is a NA 240, im more likely to get rear ended.

Definitely a possibility sliding under. Don't say I didn't warn you!!!

Also, with the bumper tucked what will you kneel on when working from the front?

RE: US spec 123 bumper mod, removing all rubber end trim - Purplecomputer - 10-23-2013

YOU GUYS TALKIN' BOUT ME?!?!?

bumpers suck. they dont do anything anyway.

RE: US spec 123 bumper mod, removing all rubber end trim - Simpler=Better - 10-23-2013

We talk about you a lot. Mostly when we're reviewing the surveillance footage.

RE: US spec 123 bumper mod, removing all rubber end trim - DeliveryValve - 10-23-2013

I have to agree the front bumpers are useless in rear ending today's type of cars. You would need to reinstall your Moose bar.... but I think it's on lgreeley's car...

Anyways a few weeks ago I did a boneheaded maneuver in my TDI and slid into the rear of a Scion. This is where 5 MPH bumpers did it's job in keeping both cars unscathed. But man it felt like I did a huge amount of damage.
The other day I had the front end off for some maintenance and driveline repairs, I could clearly see the worn off paint on how the shocks were compressed by the impact. I thought it was pretty neat to see that.

RE: US spec 123 bumper mod, removing all rubber end trim - JB3 - 10-24-2013

(10-23-2013, 11:34 PM)DeliveryValve I have to agree the front bumpers are useless in rear ending today's type of cars. You would need to reinstall your Moose bar.... but I think it's on lgreeley's car...

Anyways a few weeks ago I did a boneheaded maneuver in my TDI and slid into the rear of a Scion. This is where 5 MPH bumpers did it's job in keeping both cars unscathed. But man it felt like I did a huge amount of damage.
The other day I had the front end off for some maintenance and driveline repairs, I could clearly see the worn off paint on how the shocks were compressed by the impact. I thought it was pretty neat to see that.

.

what did this end up doing to the bumper skin?

incidentally, thats how I intend to mount the rear bumper, bolts top and bottom like that

RE: US spec 123 bumper mod, removing all rubber end trim - DeliveryValve - 10-25-2013

Both cars had some abrasions on the bumper skin paint. Luckily no permanent ripples on the plastic. It basically looked like someone parallel parking in a tight city spot.
I have yet to do it, but a little rubbing compound should clean it up.

Bumper attachment is simple, one large bolt all the way through.

.

RE: US spec 123 bumper mod, removing all rubber end trim - JB3 - 11-03-2013

so ended up attaching the rear bumper. After thinking about it, since this is a 240, id like to retain those shocks I think.

Here is what I did to mount up after that tab was missing-

welded 3/16ths U's to the shocks, and bolted top and bottom

here is how the rear bumper looks sans rubber-

now to work out the bumper ends, or if they are really needed. Might be necessary seeing as how im not tucking this one

RE: US spec 123 bumper mod, removing all rubber end trim - willbhere4u - 11-04-2013

put the rubber on and just make sure and wash it often

RE: US spec 123 bumper mod, removing all rubber end trim - JB3 - 11-04-2013

(11-04-2013, 12:23 PM)willbhere4u put the rubber on and just make sure and wash it often

I plated over the mount holes in the rear. If I rig up the stock bumper end, its going to have to be fully supported from the bumper.

Ive got some domestic bits coming to play with the ends

Doesn't look bad with no rubber though, here are a few pics-

only looks kinda weird from this angle-

RE: US spec 123 bumper mod, removing all rubber end trim - Simpler=Better - 11-04-2013

Doesn't look that bad, my truck had that much gap before it got rearended 500 times

RE: US spec 123 bumper mod, removing all rubber end trim - willbhere4u - 11-05-2013

euro bumpers would fix that issue you have already done the hard part filling the old holes Big Grin

RE: US spec 123 bumper mod, removing all rubber end trim - sassparilla_kid - 11-05-2013

I think if you could mount Euro bumpers using the American bumper shocks that would be the cat's pajamas