Assembling and final tests

 There was received necessary for assembling start new central wire harness. We received new previously missing on dashboard tachometer and speedometer.

Assembling was started installing and adjusting doors and trunk lid. Next on agenda were rubber grommets and electrical harness. Electrical harness was led through firewall into engine compartment. Cables were connected to central fuse box located on the firewall.

Through the engine compartment using new special rubber cable channels wires were led to headlamp housings.

There were attached to the cable harness different dashboard electrical devices. Now it was time to start new cable harness installation to the rear of the car.

As previously in the front part of the body also rear wire harness was put into place and all wires were led to appropriate locations.

Sound insulation was fixed onto the door inner surface. Restored door mechanisms were installed.

Door sealing was glued into door channels. Trunk lid sealing was glued around the opening into perimeter gap.

We produced and installed new leather seal plates for pedal stems, as it has been originally. Assembling of whole pedal assembly was completed. New lid opening mechanism was installed.

  Restored complete wiper unit was installed and tested. New brake cylinder and new brake fluid reservoir were installed.

New "eyebrow" decorations had been tailored to suit position perfectly. Other body mouldings were also fixed into the place. 

New chromed stoneguards were installed in place. All threaded joints which are not made of stainless steel after assembling were covered with protective coating.

Protective coating was applied on all internal hidden cavities. All usually most affected by corrosion hidden areas received additional protective treatment.

External light signalling devices were assembled.

Backside of all chromed components also received additional corrosion protection treatment before assembly. Assembled bumpers were installed onto the body.  

New white-stripe tyres were installed onto restored rims. Wheel balancing was completed.

Restored clutch pressure plate was installed onto the flywheel. Restored clutch fork and new release bearing were installed onto restored gearbox.

Gearbox was mated to the reconditioned in USA engine. Front subframe was prepared for engine installation attaching new engine-subframe and subframe-body flexible supports.  

Completed rear axle was attached to the body. We continued with joining all rear suspension and braking system components. Rear axle again is ready for the ride.

Handbrake mechanisms were installed on the rear axle. Rear brake mechanisms were completed.

Assembled "ponton" was immersed into the body and attached to the suspension points.

Front braking mechanisms were assembled.

New piping comprising brake and fuel supply lines was installed underneath the body.

Brake system was composed connecting all brake fluid pipes using new connectors.New flexible brake hoses were connected to the fixed connectors.

Fueltank was installed and connected to the fuel supply system piping.

Missing cooling system pump connection piece was produced. Cooling system pump was connected to the engine head.  

Heating system piping was installed and connected to the heating devices. Heating system was connected to the engine. 

Using new glass, new rubbers and decorations windscreen assembly was completed. Renovated side posts were attached to the windscreen frame completing this assembly ready for installation onto the body.

Hubcaps have got the last touch - centres according to Mercedes tradition were painted in hardtop colour.

Installation of the exhaust system was started to finish works underneath the car.

Restored windscreen assembly was installed onto the body.

Before assembly of the exhaust pipeline we had to restore remaining original exhaust manifold which had been lost outlet flange. Manifold outlet flange was delivered as original spare part so we had to match together whole piping system and weld this piece into the dedicated place.

Restored exhaust manifold was installed onto the engine. New exhaust pipe was connected to the manifold flange.

New intermediate silencer was attached to the body using new rubber dampers. New rear muffler was installed into the dedicated location behind the fuel tank.   

Restored front cross stabilizer bar was installed using all new rubber mountings.

Several brake booster housing bolts had badly damaged threads, so we produced new bolts. Restored braking system booster comprising new master cylinder was installed into place.

Using new wires and new shrouds were restored heating system control links.

New chromed radiator mask was assembled. 

We found and bought used inlet manifold which was cleaned by glass pellets as received.

Delivered used inlet pipes were disassembled for restoration. Carcasses of the inlet pipes were cleaned by glass pellets, whole steel and rubber piping was replaced by new items.

Braking system restoration was finished connecting brake booster and brake fluid reservoir to the braking system.

We managed to find reconditioned distributor and alternator, though upon receiving product quality appeared dissatisfactory. Alternator and distributor were disassembled to check component quality. Zinc plated parts were cleaned and sent to galvanizing workshop.

Restored distributor was installed on the engine.

New WEBER carburettors were received. We ordered corresponding intermediate plates needed to mate these carburettors to the original 190SL inlet manifold. 

Among unavailable parts were also gearshift leaver base and tunnel which were, like gearshift leaver itself, missing on given car. We borrowed original parts from another car. After inspection of given parts it was taken decision to make own copies of these missing and long sought after body parts.

Exact copies of gearshift leaver base and tunnel were produced and precisely tailored to suit restored bodywork. Finally before installation our self made body components were painted.

Dashboard was removed for installation of all new and restored control elements and gauges. Restored ventilation system leavers were connected to the control cables.

Intermediate adaptor plates were produced to mate Weber carburettors with original 190SL inlet pipe.

Door locking mechanism push bars which originally had been produced from alloy were worn out. Since such parts were not available as spares we produced and installed adequate copies from the steel. New door locks were installed into new door handles and fixed into the place.

Unfortunately received original door top mouldings were of bad quality - attachment bolts were falling off the weld spots already before installation. We had to apply modern glue to attach bolts to this chromed decoration. New improved door top decorations were installed into dedicated place.

Rubber aluminium spacers for bumpers were received and installed on the bumpers.

Waterproof plywood was used to produce new flooring panels behind the seats. Wooden frames were fabricated according to original drawings for both adjacent parts. New front floor panels were fabricated from waterproof plywood. New toolbox lid also was self-made in the luggage compartment from waterproof plywood.

Received used alternator was reconditioned and tested before installation onto the engine.

Finally reconditioned radiator was received. Seems it is a bit damaged during transportation - we shall correct attachment bolts and conduct a pressure test before mounting. There are wrong round holes in the support flanges - we shall manually make correct square cut-outs.

Current package with missing parts has arrived from one of our suppliers - not much, but any of those parts are important for present assembling process. 

As ordered last batches of the parts were arriving we may proceed further in assembling process. New steering wheel and its components including new central ring were received allowing us finish steering system installation.

As restoration of switches and other driver interface devices was completed we started assembling of the dashboard. All switches, knobs, lamps and gauges were installed in the dedicated places. Dashboard was installed and all were decorations attached using new fasteners.

New floor panel reinforcement ribs were produced from the oak and attached to the boards according to original drawings.

During restoration voltage regulator was completely disassembled and finally parameters were adjusted. Unfortunately contacts of this more than half of century old device were presenting signs of serious wear and tear so soon it would be necessary to replace completely this important component. Voltage regulator and alternator were connected to the electrical system of the car. 

New two tone horns were installed allowing go further and install restored radiator.

Long awaited starter motor finally was received and with no delay checked and installed into place. Ignition system components were connected to the wire harness. Restoration of the ignition system was completed.

Restoration of the completely destroyed by corrosion authentic ventilation fan motor appeared impossible, so new fan motor bracket was produced to accommodate suitable motor in the ventilation channel. Original fan blades and elastic supports were used. Installation and adjustment of the ventilation system was completed.

Gearbox control linkage installation was completed and sound insulation pads were attached.

Installation of new Weber carburettors and initial adjustments of the fuel supply system was completed.

As long as all apparatus were installed in the engine compartment it was time let the motor to breathe again. All oils and other liquids were filled up and engine started. Oil pressure gauge on the dashboard and our test device both demonstrated adequate oil pressure. Electrical system functionality was also tested during engine run in. Coolant leakage through carburettor heating hose junction was noticed and eliminated.

As sound insulation mats were affixed carpets were installed into passenger compartment. Carpets were glued unto body surfaces behind passenger seats - on the rear wall and new floor panels behind the seats. 

Using restored structural parts renovated seats and seat adjustment mechanisms were assembled. Seats were installed in the passenger compartment. Hard top was mounted onto body to adjust top position of the door windows and install seal between hardtop and door glass.  

 Roof moulding finally was nailed onto roof seam and roof tensioning wires were adjusted. As soft top was completed last interior decorations were put into place - roof central catch, handle and sunvisors finally found their place. New steering wheel was ready to serve driver. 

New bumpers unfortunately were missing holes for reflector attachment bolts so we made our specific brackets and attached reflectors by already existing bumper bolts. New external rear view mirror was installed onto the left wing. As the last touch leather cover for soft top storage box was installed.

We started preparations or the test drive. Braking system was checked and adjusted where necessary. Wheel alignment on both axles was checked and adjusted. Headlights were adjusted.

First test drive was not really long - just some 5 km, but it was enough to notice some things requiring corrections.

New Webers were not working adequately on all engine speeds and corrections were needed. Also ignition timing was adjusted additionally.

It was decided to combine first public appearance of the car with test drive. Our experienced test team took part in Dikli Palace annual regularity rally. Workshop test licence plates were used during this event. Event route included friendly for classic cars asphalt roads through several cities of Latvia. 

Driving regularity was checked in numerous appointed, as well as unknown for competitors, locations.

One of stages was held on race track in Riga which we normally use for our regular drive in activities. During event notes were taken and later provided to the workshop master for necessary adjustments before delivery. In total more than 700 km were covered during this test.

At the end of first participation in public event first surprise made appearance - 190SL got a prize for the best restoration judged by participants of the rally, i.e. competing classic car owners and restorers.