What’s missing?

May 20, 2007

Automatic transmissions is the shit.
No more than two pedals are required, lol, so I threw out the clutch and it’s associated hydraulic cylinders, pipes and reservoirs.

Picture says: no more pedals than a car needs!
Two pedals

This was definitively a PITA-type of job. The bolt holding down the pedal assebly is almost impossible to reach. But I did say almost, and I did remove the excessive clutch pedal. 🙂

Done: hood cleaning

May 20, 2007

I didn’t mention this before but as the car sat in it’s previous location it experienced a slight mishap. There was a water leak for a week, with water running down from the concrete ceiling, dripping limestone all over my car (note: of all cars in that garage only Franz was affected..). Hadn’t given this much thought until it was time to put the hood on. Oh the humanity, this took me an entire day to clean up with rags and excessive spraying of limestone removing chemicals.
This is what it looked like..
Limestone covered hood

Not only was the hood affected, the passenger door and much of the front was covered in this mess to. It’s all gone now though. 🙂

Old sins

May 20, 2007

When I had installed the neutral safety switch the ingition lock didn’t engage the starter in Park. I thought this was due to a faulty neutral safety switch so I pulled it completely apart like advised this instruction. Very good instructions but I found out the switch was working properly… :/ Could call this wasted two hours but now it definitively will work for a long time, it’s all degreased and lubed up!
I located the fault to my home made transmission lever being too short, so I did lengthen it about 3cm’s, now the safety switch works as it should. Pictured below is the lever.
Tranny lever

Added bonus, modified connector to reverse lights. Original W111-style connector at left and new connectors at right matching the 722-tranny.
Reverse light cable

Done: Battery tray relocation

May 20, 2007

This involved some welding. Had two different trays, none which would fit inside the narrow space between chassis and intake manifold, so I made my own. It fits very nicely, all done by scrap iron found on the property. The battery is a brand new 80Ah el cheapo battery.

Here’s the space before
Battery tray 1

Freshly painted
Battery tray 2

Please note this is the sport edition of battery trays, as you can see no excess weight exists in this tray with all the holes in it.

Installed in car
Battery tray 3

With battery in place
Battery tray 4

Bonus: clearance test video with hood installed

Done: Vacuum system

May 20, 2007

Here’s a real ghetto-tech approach to the vacuum system.

A day spent at a pull-a-part resulted in a bucketfull of vacuum hoses, connectors and orifices. Nice start for a couple lousy bucks spent!
Vacuum hoses

Got a great drawing from this forum post, it’s the first drawing. I haven’t a slightes clue what parts 1 & 2 on the drawing are but nevermind, it’s all connected together and there’s no loose ends. Expect a follow-up on vacuum troubleshooting 🙂
Here’s a picture of the result. The big black roll of hose with the aluminium block is a shutoff valve, I eventually did install it inside the car.
Vacuum hoses mess

Done: Oil cooler

May 20, 2007

oil cooler mounted
Got myself an oil cooler! A friend has a for-parts-W108 sitting in his barn, he said go ahead an pick whatever you want so I did.. His oil cooler now sits in the front of my car (that is, after cleaning it, picking out two spiders and giving it a light coat of black paint). Also got myself some hydraulic hoses (again from AMAB Hydraul as were the earlier ones) to connect the cooler to the oil filter.
Here’s the result.

New tenant

April 29, 2007

Not much new today, just wanted to say that I finally lowered Franz to the floor and he’s now sitting on his own @ss. What a difference this made, having seen it two feet up in the air the last six months.. And it was propably five years ago since I last saw it with an engine up front. The new engine bogged down the front end quite a bit and it looks cooler than I remembered.
Front end shot

And there’s a new tenant in the shop too. A 1977 Mercedes Benz 307D auto-transporter!
Rusty bastard, frame was split in half so we’ve done a lot of rust repairs today. A quick glance in the engine bay told me it’s a OM616-engine in there and it is mated to a four speed manual.
Transporter frontTransporter work

The transporter deal included two other 307D-vans, one without engine and the second one with reputedly a OM617 and a five-speed manual in it.

The diesel benzes now outnumber every other category of vehicles in the shop!

That’s all folks..

Master plan

April 22, 2007

Here’s what’s coming soon:

  • A new home for the battery
  • Electrical hookup to starter, battery, glow plugs and whatnot
  • Vacuum system. Don’t know much about it so pray for me
  • Air filter housing. I don’t have this yet so I don’t know how much space it takes
  • Oil cooler. Got to get my hands on one first.. I think it will fit under the main radiator
  • Stay tuned.

    Hot and cool

    April 22, 2007

    This is what’s been up lately..

  • Radiator and all hoses are mounted
  • Exhaust system completed
  • Oil filter mounting completed
  • Shift stick linkage completed
  • Let’s begin with the radiator

    It was a fairly easy job. I used a standard Behr-radiator that came along with the 300D-engine. Has an transmission oil cooler in the bottom. The Behr is a bit narrower than the original ’68 radiator so I created simple mountings that holds it firmly in place, shown here:
    Radiator mountings

    Here’s the completed assembly with all the hoses connected. The transmission cooler lines are connected but not shown in the picture. Note how well the heater water connection connects up:
    Radiator assembly

    Then the exhaust system

    The front part came also along with the engine and fitted surprisingly well. Okay there wasn’t much marginals between the steering linkage but it did go in. Everything after the foremost part was the old pipe from the W110.
    Here’s the front part
    Exhaust front part

    And a shot from underneath, some cutting and welding hade to be done for the W123 and W110-parts to talk to each other:
    Exhaust underneath

    The oil filter relocation is also done

    Here’s the completed oil filter plate adaptor
    Oil plate adaptor complete
    (Thanks to Conny for some fabulous welding!)
    The small pipe in the bottom is for the oil pressure line. This normally comes out of the filter housing but not anymore on this engine..

    A closeup of the installation
    Oil plate adaptor installed

    And an overview (a bit messy picture)
    Oil plate overview

    Finally a word about the shift stick linkage

    A pretty straight forward job, there was a clear path from the shifter levers down to the transmission, so all I did was make up an appropriate lengt rod with connectors at each end. Missed to take a picture of this and it’s useless to shoot one now, but if you ever find yourself doing this same job you’ll find the job a piece of cake.

    Other things

    I have to relocate the battery to somewhere else, this is what I had in mind. Inspired by the later models.
    Battery new location?
    It’s the rusty plate with traces of blue in the picture. Fits in to that space, just have to fabricate something that attaches it to the chassis. This is a job for another day though.

    That’s all for now.

    What’s cooking? Oil of course!

    February 20, 2007

    Lack of updates for more than a month, is this project mothballed? No!

    Work has been going on although at a slower pace than before.
    Temperatures here in Sweden has been below 0oC and the shop had no heating what so ever so temperatures there were also .. sub-zero.
    Last week I managed to get my hands on a diesel fueled heater so now we’re able to maintain about 15oC and that’s quite ok.

    Enough rambling, what’s cooking?

    First I did some shortering of the cardan shaft to accomodate the longer 722-transmission (the original transmission is so laughable small it could be from a small motorcycle..). Here’s a picture of the very scientifically exact method (this is a “not joke”..) used in joining two parts of cut-up cardan shaft.

    Cardan shaft cutup
    The leftmost part is what I cut from the W123’s cardan, and the rightmost part is what I took from Franzes original parts. Another picture showing length comparison of the part that I removed from the W111’s cardan, compared to the finished result.

    Cardan shaft cutup
    All in all I think this new combo is about 12-13cm shorter than it was before. It’s only temporarily welded together as you can see, I’m not going to weld this together myself since the end result propably would vibrate my car to pieces.

    Finally a picture of the entire drivetrain assembly.. or not. Quite impossible to take such a picture so this is for your pure Benzophile enjoyment. I promise though, the cardan assembly is all there! Really. Even test fitted the engine again and it all fits perfectly.
    Drivetrain all there

    Use the grease, Luke… I’ve managed to negotiate a deal with a local falafel restaurant, they’re giving me about 20 liters (5 gallons) used cooking oil a week. Nice deal so far since I even haven’t got the car put together.. Oil seems to be of a good quality, did the frying pan test and it shows no water what so ever. Cool! So time to start filtering, bought some nice oil drums to make a filtering assembly of, it’s going to be very similar to this. Here’s a WVO porn picture of the to-be-refinery-drums.


    Poured over the oil I’ve got so far (2 20 liter buckets) in one of the drums. Man this sh-t stinks horribly! And the stuff I found at bottom of the buckets.. almost threw up on looking at it. The good part is of course that the oil had settled fairly well and left some 2 liters per bucket of this yellowish sludge that I definitively not need in my engine.

    Did some shopping too.

    Found a nice set of injection line heaters on eBay, here’s a pic (fresh outta box). Seller says it will heat up the lines to about 90oC and I have yet to test this but have so far no doubts about it.

    Line heaters

    And finally a real cool deal, got this from UtahBiodiesel Supply. No greaser is complete without one! Matches nicely the original 230S-badge even though it’s made to imitate the W123’s lettering style.

    Biodiesel badge

    That’s about all for now.