Bodywork repair

Ordered original body parts were received from supplier.

Borrowed doors from donor coupe were cleaned manually before further works.

Right hand door was damaged – it had rather deep dent to repair before further use.

Front wings from donor vehicle had severe corrosion damages which we had to repair before further use of these components.

Right side front wing also had damaged headlamp housing, though comparing to opposite side it looked less dramatic.

Suitable parts were moved to welding shop and stored for further use during course of restoration.

Body was moved to the sand blasting camera to clean all repairable surfaces.

Most of completely damaged panels were removed already before treatment in sand blasting camera.

Rear end was completely cut away before cleaning providing access for cleaning of some still survived panels.

Firewall had damages along the whole surface.

Air inlet hatch was composed from several layers of metal which all had serious damages.

Inner front wings were almost completely destroyed by corrosion.

Outer doorstep profiles were cut away providing clear view on completely destroyed structure.

Nothing real was keeping together middle and rear parts of the car.

Front cross member consisted of some remnants.

Dashboard carcass was damaged, but repairable since it had no serious corrosion damages.

Remains of the body were installed on our welding rig.

First front panel and front cross member were removed.

Damaged areas of the front longitudinal members were cut away giving space for fresh metal.

New inner part of the front cross member was fixed into the place.

All elements of front longitudinal members were restored using metal of appropriate thickness.

As welded, all restored structures were primed to protect against corrosion.

New towing bracket was received for welding onto the new front cross member.

New outer part of the front cross member was welded into the place and protected by primer – both, inside and out.

Remnants of the damaged front inner wings were cut away.

This component is completely destroyed by corrosion – we could use it just as reference piece for recreation of given structure.

Firewall had countless number of corrosion damages.

Damaged areas were cut away to provide space for precisely tailored replacement panels. All discovered corroded inner surfaces were cleaned and sprayed by protective agent.

Replacement panels were self-made exactly to required shape and size.

All patches were welded into the places

After welding all seams were ground and covered by protective primer.

Damaged firewall areas were cut out.

Adequate replacement patches were produced for firewall reconstruction.

Outer panel along the windshield was destroyed by corrosion.

We cut away outer layer of the panel and found even more corroded next layer underneath.

Through these holes water easily penetrated into the passenger compartment.

We removed this damaged layer.

Structure under damaged panel was also affected though on less dramatic extent – it was possible to save it.

Remaining parts of the firewall panel structure were cleaned to get at full picture of the damages.

Rust modifying reagent was applied on the most damaged areas of the panel.

All cleaned surfaces were primed before further restoration works.

Replacement panel from donor car was prepared for installation – it was cleaned, repaired and protected against corrosion.

Replacement panel was welded into the place.

At this stage shape of the dashboard carcass was restored.

On the left hand side of the passenger compartment side wall was unrepairable.

Damaged component was carefully cut away ensuring adequate copy could be self-fabricated.

New passenger compartment side wall was self-made and prepared for installation.

Other removed structural components were kept as samples for replacement manufacturing.

New parts were welded into the place to restore whole structure.

As this area of the body was finished all seams were ground and covered by protective primer.

Pieces of damaged firewall areas were used for fabrication of copies.

Copied patches were welded into the place and weld seams were ground.

Protective primer was applied at the end of panel restoration as usual.

Luggage compartment spring housings were painted while body was under restoration.

Many components of the original car were not restorable. Unfortunately some items were not available from parts suppliers as well, so we had to use those from our donor car.

To retain correct shape of the needed components any of those was carefully removed. To achieve it, we had to drill out each and any weld spot of the body.

Task was quite complicated in some areas since there were joined together in certain sequence several layers of metal.

This separating activity was performed on all needed panels.

Inner front wings were also separated from front longitudinal members.

Completing this task it was necessary to follow original assembling technology in the reverse order.

Acquired components were also damaged by corrosion, though condition was much better than for counterparts on original car. We cleaned and repaired those components before installation onto the project car.

This panel was rusty though we expected it had no holes penetrating through metal.

Removed panel was brought to sand blast camera for cleaning. After cleaning we noticed that in some areas along the flanges corrosion had been severe and we had to produce and replace these damaged sections before panel was ready for further use.

All remaining panels were left in good order since we may need some additional part during course of the project.

Similarly we detached rear panel under the seats – this complicated piece was not available from spare parts suppliers, but our project car was missing it completely.

Remnants of the donor car was moved to storage until further activities.

Front floor reinforcement profiles were heavily damaged by corrosion.

We cut out damaged areas of the front floor reinforcement profiles to manufacture suitable patches for substitution.

As new sections were welded into the place seams were grinded and received protective coating.

Internal surfaces of the floor reinforcement profiles after cleaning received protective treatment.

Inner front wings acquired from donor vehicle were repaired prior to installation on our project.

Both damaged inner front wings were carefully removed providing space for substitution components

Previous inner front wings were completely destroyed by corrosion.

Remaining panels also had damages caused by corrosion which we had to repair first.

Damaged areas were cut out and corresponding patches were fabricated.

As fresh metal was welded into the place restored area was prepared for further works.

Prefabricated front inner wings were welded into position.

Missing segments were fabricated and welded into corresponding areas.

Missing parts of the bodywork structure were fabricated and prepared for welding into dedicated place.

Damaged areas of the inner wing reinforcement profile were cut out to provide space for self-fabricated replacement patch.

Prepared patches of the reinforcement profiles precisely lied into the dedicated places.

Weld seams were grinded and protective coating applied as junctions between inner wing reinforcement profiles and front door pillar were welded into the place.

Radiator opening sill had severe corrosion damages and the only way to restore it was self-manufacturing of exact copy.

Precise copy of radiator opening sill was produced and prepared for installation.

Upper part of the radiator opening was removed from previous front panel and prepared for installation onto the renovated front structure of the body.

Both parts of the front panel were tied together by welding into the place upper panel and sill of radiator opening.

Acquired from donor vehicle and repaired windscreen panel was prepared for installation.

Hidden under the windscreen panel insulation rubbers were disintegrated so new inserts were ordered for restoration of the bodywork.

New insulation pieces were attached to the intermediate front panel before welding of outer shell.

As new front panel was fixed into the position all seams were grinded and protective coating was applied.

Doors from donor vehicle were prepared for installation.

Structural areas of the front wings were cleaned in sand blast camera preparing wings for repair.

Headlamp housings had serious damages caused by corrosion.

Wing outer surfaces around front edges were damaged by corrosion.

Both wings had penetrating corrosion damages on the front panel below the headlights.

Lower parts of both wings along attachment flanges to the doorsills were destroyed by corrosion.

Damaged by corrosion housing segments were cut out.

Removed segments of damaged areas were used for self-manufacturing of the exact copies for substitution.

As substitution segments were welded into the place welds were cleaned and protected.

Small damages were plugged by welds, but bigger damages we repaired substituting whole damaged areas.

Removed segments were used for self-manufacturing of the exact replacement patches.

Bottom edge segments were self-manufactured for both front wings.

Prepared segments were attached to the front wings.

Damaged sections of the front wing attachment flanges we cut away to replace.

Precise copies of damaged front wing flanges were produced.

After repair front wings received protective treatment.

All removable components of the front part of the body were assembled to check compatibility.

Damaged junction piece of the front wings was first repaired.

Junction piece of the front wings precisely fit between restored front wings and new front crossmember.

As new junctions between door pillars and front inner wings were fabricated gaps between front wings and doors were checked at this stage.

Enemy which never sleeps had been working hard leaving traces under original fifty years old paintwork. There will be needed additional treatment of all external surfaces to prevent further corrosion damages.

Rear wing inserts on both sides were almost completely destroyed by corrosion so not much was left to make a copies of these unavailable components.

Inner parts of rear wheel arches were almost completely disappeared because of corrosion.

It was not possible to use as a sample separated remnants of the rear wheel arches.

Not much was left from rear longerons.

We removed all destroyed by corrosion items providing access for cleaning of hidden areas at the rear of the passenger compartment.

New components were prepared for welding operations.

Spillage channel of soft top storage box was completely disintegrated by corrosion.

We cut away all remains of this structure.

Rear wall of the soft top box and side reinforcement panels were still in repairable condition.

We removed from wheel arch reinforcement panels almost completely disintegrated rear wing support plates.

Using remains of original items we produced copies for substitution.

Side sections of spillage channels are also not available from parts, so we self-manufactured adequate copies.

Soft top storage box along the rear wheel arch flanges had serious corrosion damages.

Damaged sections of the cabriolet roof storage box floor were cut off and corresponding new patches were self-manufactured.

Soft top tensioning bolt locations had serious corrosion damages.

Damaged areas were cut out and precise substitution pieces were tailored.

First shape of sheet metal parts was restored.

Finally threads were welded into the place.

Passenger compartment rear wall had penetrating corrosion damages along the wheel arch flanges.

Damaged sections of the rear wall were cut off and exact replacements were prepared.

As new segments welded into the place welds received usual treatment.

Stiffening pieces on the side reinforcement plates were completely disintegrated by corrosion. No doubt such pieces are not available from parts.

Damaged items were removed and precise copies were tailored.

New parts were welded into appropriate places.

Now prefabricated side sections of spillage channels were weld into position.

Self-made rear wing support plates were welded onto side support plates.

We prepared for installation rear part of spillage channel, which we acquired from parts.

All sections of spillage channel were joint together.

Expecting arrival of the ordered new inner doorstep sections we moved our works on central section of the body.

Additional supports were placed in the body and remains of the doorsteps were cut off.

As expected central crossmember had serious corrosion damages on all surfaces.

Doorsteps went straight to scrap pile.

We expected that central crossmember from our donor car should be much better.

Even top surface of passenger compartment rear crossmember had serious damages and diagonal members were hanging almost in the air.

Unfortunately received from supplier doorstep profiles appeared wrong – steel thickness and shape both were incorrect.

Received profiles were missing specific for coupes and cabriolets recesses for seat accommodation, so we had to send these items back and wait for replacement.

Since appeared that also outer pieces of rear wheel arches provided to us are from sedan model we took decision use existing items from our donor vehicle.

First rear wings were cut off. Reinforcement plates of outer rear wheel arches were different on coupes and cabriolets, so we should expect careful drilling off unnecessary components.

We cut out both rear wheel arch structures.

We carefully drilled off also rear passenger compartment crossmember with diagonal members – this structure was almost completely disintegrated on our car.

Rear crossmember with diagonal members was in decent condition and just some repairs were needed before installation.

Central crossmember on our car was also in poor condition, so we removed corresponding item from donor vehicle.

Even without any rust protection this piece had been survived almost without corrosion damages.

At the rear end we had one more necessary component which was missing on our car and which is not available from parts.

We carefully drilled off front section of luggage compartment floor, which was completely destroyed on our car.

Remains of the donor car were stored until further necessity.

Upper surface of the floor under rear seat was cleaned from tar earlier to facilitate drilling off.

We had to clean from protective resin also bottom surface of acquired piece.

It was not possible to clean protective resin by sandblast, so we did it manually.

It was necessary to remove from acquired components all unnecessary slices of remaining metal before we can repair and clean these elements.

Unnecessary segments of metal were removed drilling out weld spots one by one.

It was not possible to remove bottom protection resin in the sand blast camera so we did it manually.

Rusty areas of acquired components were cleaned in sand blast camera.

Surfaces forming hidden cavities were covered by protective coat.

Outer surfaces of acquired components were covered by primer.

Remains of the rear passenger compartment crossmember with diagonal members were removed.

Hidden by remains of rearmost crossmember there were numerous corrosion cavities of massive central tunnel.

Damaged areas were cut off and replaced by fresh metal patches, smaller cavities were repaired by weld plugs.

Restored section was cleaned and covered by protective coat.

Acquired rearmost crossmember was precisely tailored to suit our project car.

All unnecessary metal slices were removed from rear wheel arch assemblies drilling out welds spot by spot. Thus prepared units were ready or the next stage of preliminary works – repair and cleaning.

Restored backbone of the body was primed prior to further recreation works. 

Pile of unnecessary scrap was separated from our valuable acquisition.

It was not possible to clean protective resin by sandblast, so we did it manually.

As protective resin was cleaned manually, prepared components were sent to sand blast camera.

Rear spring supports and adjacent panels were seriously damaged by corrosion.

Perforated by corrosion components were cut off for repair providing access for cleaning of inner surface of the cross member.

Spring supports were repairable, but crossmember body sections were too bad for repair and we had to manufacture adequate to remnants fresh copies.

Restored rear spring supports and rearmost body cross member inner surface were primed prior to further works.

For detailed defects detection we manually removed paint from luggage compartment lid. Corroded spots additionally were cleaned in sand blast camera.

Outer shell of the luggage compartment lid was seriously damaged by corrosion along the whole rear edge.

Frame structure of the luggage compartment lid was damaged by corrosion along the whole rear edge.

Acquired floor panel under rear seats was cleaned in the sandblast camera.

Acquired forward part of the luggage compartment floor was cleaned in the sand blast camera.

Prepared wheel housing assembling units finally were cleaned in the sand blast camera.

Acquired rear wheel housings and joint body components were primed prior to installation.

There appeared several corrosion damages on the air intake channel cover around the cut-outs for wiper shafts which we had to repair.

Corroded cavities were plugged by welding and grinded.

Broken seat carcasses after cleaning were welded before further seat restoration works.

Damaged passenger compartment side panels were cut off giving place for acquired components.

At this stage body did not existed as united entirety – just phantasmagorical ties were keeping together front and rear parts of the body.

New rear longerons were prepared for installation.

Prepared new rear longerons were tailored into the place again providing connection between front and rear parts of the car.

Diagonal members were welded to the new rear longerons.

We installed acquired wheel housings. There was perfect fit to new longerons in the luggage compartment area.

As delivered longerons originally were produced as repair size components, there appeared gap of some inch between wheel housing and longeron profile in the passenger compartment area. We had to modify both longerons to achieve compatibility to wheel housings, interior floor panels and rear seat.

Missing sections of the rear longerons were self-fabricated.

As tailored items were fixed in place weld seams were grinded.

Corrected sections of the rear longerons were primed prior to further welding works.

We prepared received new luggage compartment main floor panel for welding.

Missing bracketing for fuel tank attachment which should be welded to the luggage compartment floor was self-fabricated.

Doorstep outer profiles were prepared for installation.

New floor pan preparations were prepared for welding.

Prior to the welding surfaces of the front floor reinforcement profiles, creating further hidden cavities, were coated by protective coating.

Prior to the welding surfaces of the front reinforcement profiles, creating further hidden cavities, were coated by protective coating.

New components for recreation of recesses in the luggage compartment were prepared for welding.

New rear panel was prepared for welding.

Diagonal bracket used for spare wheel support and carriage of jack was broken, so we had to repair it before further use.

Restored diagonal bracket was primed before welding into the place.

Door lock threaded plates were restored before installation.

Acquired wheel housings were joint to existing body side reinforcement profiles.

Doors were installed to check compatibility of new structural body parts.

Today finally arrived new doorstep inner profiles, which were delayed from supplier for a couple of months, providing us now possibility to move further with body recreation.

Received new doorstep inner profiles upon delivery already had corrosion spots.

To avoid further corrosion new profiles before welding were cleaned and spread with protective coating.

Prefabricated doorstep inner profiles were welded into the place.

Rear wheel housings were joint to the new doorstep profiles.

Wheel housings were welded to the other body structural components.

Acquired wheel housings still had damaged areas to replace.

Damaged segments were cut off for preparation of substitution parts.

Precise copies of the damaged areas were fabricated.

Fresh metal patches were welded into dedicated places recreating wheel housings.

It was necessary to substitute damaged segments of the folding roof storage box floor.

As jack holding devices were welded into doorsteps we started restoration of door pillars.

Remains of the door pillar were joint to the new doorstep profile.

New cover plate for door pillar junction was produced.

We finished reconstruction of the lower ends of the front door pillars.

Acquired floor pan under rear seats was welded into the place.

We removed for repair damaged central cross member.

Previously hidden surface of the central tunnel was cleaned before further restoration works.

Prepared new floor panels were welded into the place.

Weld seams were grinded and covered by protective primer.

Restored wheel housings were covered by protective primer.

Front part of the luggage compartment floor and cross member were welded into the place.

Damaged areas of the firewall were cut off to produce new segments for substitution.

Adequate patches were prepared for firewall restoration.

Tailored pieces were welded precisely in the place.

We prepared for welding new outer profiles of the doorsteps.

Doorsteps were closed by welding of outer profiles.

Instead of damaged we manufactured new doorstep rear end closings for welding into rear wheel housings.

Reconstruction of the rear end of doorsteps was completed.

We manufactured patch panels for restoration of passenger compartment side walls.

Side wall of the passenger compartment was joint to new doorstep profiles.

New doorstep front end cover panels were prepared for welding.

Front end of new doorstep profiles was closed.

We produced patch panels using remnants of the firewall reinforcement profile.

Firewall reinforcement profile was reconstructed.

Floor reinforcement panels were prepared for welding.

Floor bottom and front reinforcement panels were welded into the place.

We prepared adequate patch for plugging of unnecessary hole on the engine tunnel.

As patch was welded into the place all seams were grinded.

We restored flanges of the central crossmember.

Damaged seat attachment brackets were restored before welding in place.

Restored central cross member and seat installation brackets were welded into the place.

Missing segments of side panels were manufactured and welded into the place.

Weld seams were grinded as new segments were welded into the place.

All restored structural components were spread by protective primer.

New rear panel was first attached to the longerons for detailed adjustment.

New rear wings were prepared for installation.

As correct measurements were achieved all components of the rear end were fixed together.

As rear panel was joined with rear wings all weld seams were grinded.

During the restoration process all gaps were continuously monitored.

New parts of the luggage compartment recesses were prepared for welding.

As luggage compartment „pockets” were restored, all weld seams were grinded and covered by protective primer.

Rear edge of the luggage compartment lid was in sorry state requiring replacement.

We cut off damaged surface of the luggage compartment lid outer shell.

Frame of the lid was also damaged by corrosion and it was necessary to replace it as well.

We cut replacement panel from luggage compartment lid of our donor vehicle.

Inner surface of acquired panel was also affected by corrosion so we cleaned it and applied chemical reagent to ensure corrosion process is eliminated.

Prepared edge of the luggage compartment lid was welded to the place.

Fuel filler lid had internal corrosion resulting in several dents.

We cut away damaged area to gain access for cleaning of internal surface.

As adequate patch panel was welded into the place, restored fuel filler lid was installed onto new rear panel to check compatibility.

All luggage compartment accessories brackets were cut off the remnants of old panels and prepared for welding into dedicated positions.

Luggage compartment lid spring supports were cut off the remnants of rear wheel housings.

Acquired parts were cleaned and repaired before welding into the place.

Spring support brackets were welded precisely in place.

New rear luggage compartment floor panel was prepared for welding into the place.

Luggage compartment floor panel was welded into the place.

During restoration of the rear end of the body all gaps of adjacent areas were continuously monitored.

Luggage compartment lid sealing rubber channel had penetrating corrosion damages.

We cut out damaged areas and produced precise patches for substitution.

New elements were welded into the place restoring channel.

Rear edge of the passenger compartment opening had serious corrosion damages and most affected segments were cut out for substitution.

New segments of rear rubber seal channel were produced for junctions with new rear wings.

Removed segments of the rear edge were used for fabricating of precise copies.

Using self-fabricated items rear wings were completely joint to the upper body panel.

As all panels were welded into the place we started final adjustments of the body.

New sealing rubber and restored locking mechanism were installed to check functionality and gaps of luggage compartment lid.

All necessary adjustments were completed during centring of the lid.

Even gaps were ensured all around the lid perimeter.

Adjustment of the rear wings and luggage compartment lid was completed.

Now restored door locks were installed for precise tailoring of the door gaps.

It appeared that holes for door latches on the new wings have completely wrong pattern – there was different measurement and no central opening to accommodate rivets of the latches was produced.

We re-worked new wings to facilitate installation of door latches in correct position.

New door strikers were installed for tests and door adjustments.

All necessary adjustments were completed achieving adequate and equal door gaps.

New original rubber profile was used installing self-manufactured separator plates between wheel housings and rear wings.

As separator plates were welded into the place protective coating was applied.

Before final adjustment we cleaned manually from both sides engine hood acquired from our donor vehicle.

Trying to install restored engine hood lock it appeared that engine hoods are not compatible – we had to replace either completely front part of the hood frame or use original cabriolet hood. Lock on the cabriolet was almost two times bigger that counterpart on coupe.

We cleaned manually original engine hood of the cabriolet to investigate possibility to use it for our restoration project.

Unfortunately condition of this engine hood was much worse comparing to item acquired from our donor, so it was taken decision to replace just hood lock panel.

We carefully cut out necessary component for our project from original cabriolet hood.

Looking on this picture it is obvious that both cars have had completely different locking mechanisms.

Original cabriolet hood locking mechanism plate was welded into the position.

Restored locking mechanism was installed ensuring necessary adjustments of restored body components.

Necessary adjustments were carried out ensuring adequate and even gaps around the engine hood.

Engine hood tensioning planks were cleaned for repair.

Tensioning planks were painted before installation in place.

Acquired used front wings had several damages which we had to repair ensuring compatibility of all adjacent components.

We had to work on front wings achieving perfect fit with headlamp chromed decoration rings.

Damaged surfaces were spotted achieving consistent gaps all around the headlamps.

Tin loading was applied along the weld seam of the luggage compartment lid.

Tin loading was applied along the front edge of the engine hood achieving perfect fit of the chromed engine mask surround.

We continued spotting of the damaged used panels achieving correct shape of the surface. We used this method working on front wings, doors and hood surface.

Doorstep cover profiles were restored and prepared for painting.

Restored muffler attachment brackets were welded under the luggage compartment floor.

Restored body cover plates were installed and sealed into dedicated places.

Assessment of all chromed decorations was completed while body was fixed onto welding rig.

Completed body was removed from the welding rig.

Body was installed onto transport rig for delivery to the paintshop.

Body with chromed decorations was delivered to the paintshop for further works.

We manufactured missing fuel pump attachment plate.

Rear side window guides were damaged by corrosion.

We manufactured damaged sections and welded to the remnants of our parts.

We self-manufactured from brass and steel missing decoration parts and sent all these for the chroming.

We self-manufactured covering for rear window recess suitable for seat belt installation.

Final decision had been taken: Project car stays with original factory colour, which is the paint code MB158. The interior and top will stay factory dark blue, so corresponding orders are placed at suppliers.

All removable body components were prepared for painting separately.

Primer was applied to all cleaned and prepared surfaces.

External surfaces of all components got additional treatment achieving smooth appearance.

After cleaning and priming all surfaces of the body shell received necessary treatment.

All weld seams were protected by seam resin.

Internal surfaces of the body were painted in final colour.

Original paint scheme was applied painting all body compartments.

Body and components were prepared for application of the bottom protection layer.

Bottom of the body and all exposed surfaces of removed components were covered by protective coating.

As interior and bottom surface was painted body was delivered to the assembling workshop.

All painted removable body components were delivered for assembling.

As exterior painting was completed car was delivered to the assembling workshop.

Underside of the body was painted according to Mercedes traditions.

Unfortunately delivered for assembling front wing splash panels were from another model, therefore we had to restore original parts for installation.

Available splash guards were sand blasted and repaired before painting and subsequent installation.