Assembling and final tests

There was delivered main batch of the ordered spare parts. New and restored parts were shelved waiting for further assembling.

New tyres were ordered and received for wheel assembling.

Body was prepared for further assembling process.

Batch of the parts arrived for assembling after galvanizing.

Restored air bellows were attached to the body. Restored car body was separated from the transport rig which was used during welding and painting processes.

Front axle on the assembling rig was moved to the installation position and attached to the body using new elastic suspension elements. Restored front stabilizer bar using new rubber items was attached to the body and front axle. Restored steering linkage was assembled using new ball joints and steering damper.

Rear axle was attached to the body by means of new rubber suspension elements. New shock absorbers and restored stabiliser bar was used for rear axle installation. Restored rear suspension levelling system was installed.

Restored parking brake mechanism was installed into the tunnel and connected by means of new cables to the rear axle mechanisms.

Overhauled steering booster was tested and adjusted before installation.

Restored wheels were installed onto the axles. Since this moment car again was able to move on own wheels though assistance of muscular power was needed.

New cable harness was led through firewall to the locations of all devices consuming electricity. New rear wire harness was installed in appropriate way into luggage compartment.

Steering shaft of the restored steering column was attached to the steering gear. Steering wheel, as well as overhauled steering wheel lock, was fixed into place.

Restored air filter housing comprising new filter element was installed into the place. Restored air reservoir was mounted behind the left wing.

Finally we received original material for firewall insulation which was immediately tailored and applied to the firewall surface ensuring further installation of the engine compartment wiring and piping.

All piping from the underneath of the body was led to the engine compartment. New air lines were connected to the restored air distribution module.

All restored control systems and grounding wirings were mounted onto firewall prior to engine installation.

Components of the electrical system were mounted onto firewall.

Engine bay was fitted with all necessary ancillaries and prepared for engine immersion.

M189 is the biggest unit installed into the W111 body so immersion of the engine in the tight engine bay requires accuracy and diligence.

New engine support bellows were used to fix the engine in the place.

Headlight units were installed onto the car. We started installation of the restored rear lamps, just still missing one of new rubber gaskets was preventing installation of the left lamp.

All new pipes were guided along the bottom of the car according to original scheme to avoid hampering installing gearbox support plate.

Also at the rear end all pipes were arranged accordingly.

Handbrake cables were installed into the central tunnel and connected to the other components

Restored gearbox support plate was attached finishing installation of the power plant.

 Sound insulation panels were attached to the floor panels in the rear seat area. Sound insulation mats were attached to the passenger compartment side panels.

Side window winding mechanisms were assembled and installed. As sound insulation panels were attached to the inner surface of the doors and window winding mechanisms were mounted into the doors.

Leather trimming was glued over appropriate areas of the soft top storage box.

Leather trimming was applied along the windscreen frame and on corresponding dashboard sections.

Disassembled for restoration quarter window opening mechanisms were assembled from restored parts.

Restored door locking mechanisms were mounted in place. Restored door handles were attached to the doors.

 Prior to installation broken air ducts were repaired. Ventilation and heating unit was installed under the dashboard and connected to the windscreen defroster ducts.

Air ducts from the heater unit to the rear section of the passenger compartment were installed over the central tunnel. Heater unit was connected to the engine cooling system in the engine compartment.

Handbrake mechanism was installed under the dashboard.

Engine piping was arranged and fixed around the power plant.

Electrical harness was led to the consumers around the engine.

Restored windscreen washer pump was installed under the dashboard and connected to the system.

Received belt tensioner bracket with pulley was restored and mounted into the place.

Finally we received radiator with replaced core and installed it into the place.

Before installation we washed and cleaned windscreen. Glass had several deep scratches along the perimeter so we had to send it to specialist for polishing before installation.

Restored rear lamps, boot lock and chromed decorations were installed into the place.

Restored chromed trim elements were attached to the frame before windscreen installation. As received new windscreen rubber was paired to restored windshield.

New woods were tailored to match restored soft op frame. Soft top frame was installed and adjusted prior to new soft top spread composing.

Finally appropriate to the model overhauled bumper parts arrived for assembling.

Windshield was installed in place providing us possibility to continue with dashboard composing.

All interior panels were trimmed by new leather.

Side windows were fixed into re-plated frames and attached to the window lifter mechanisms.

Door windows were mounted unto door window lifter mechanisms.

Attached windows were adjusted against the soft top frame.

Restored front lamps were installed and connected to the electrical wiring. All checked electrical devices were connected to the new wiring.

Whole electrical system was accessed before battery was connected.

We started adjustment of new soft top structural woods preparing frame for roof assembling.

New rear bow was precisely tailored to suit the frame and fixed into the place. New nailing pad was tailored from special leather and fixed into position on the front bow.

Engine was filled with all liquids and tested on leakage.

Complete exhaust system for 300SE was not available on the market, so using delivered silencer and muffler we recreated whole system from remaining usable parts and new piping. Exhaust system pipes before installation were coated by heat resistant paint.

Engine was started for the first time since beginning of restoration process.

Unfortunately during engine test it appeared that water pump flange has too severe corrosion damages and even new seal cannot compensate such loss of material so we had to remove pump body to remanufacture flange.

Front bumper was assembled and installed onto the car.

Rear bumper was assembled and installed onto the car. Number plate illumination lamp is not available from new parts, so we polished existing alloy body before installation.

Air suspension system was filled with air and was keeping suspension level already for second week still that.

Some of missing components left on our backorders at suppliers were delivered prompting assembling process.

Received soft top sealing rubbers were installed into re-plated guides ensuring final adjustment of the side windows.

New OEM steering wheel was received for assembling.

New interior mirror glass and all restored parts were gathered together for assembling. Restored mirror was prepared for installation.

New exterior mirror glass and sealing parts as well as restored housing were brought together for assembling. Restored mirror was installed onto the door.

Front emblem was damaged and it was necessary before installation restore it. Cleaned radiator net was furnished with re-plated surround and new polished bars. Restored escutcheon, emblem and Mercedes star were installed onto radiator mask.

Headlamp surrounds were installed onto the lamps.

Air inlet grille with cover plate was installed over air intake aperture.

First pre manufactured headliner was attached to the softtop frame bars.

Over the softtop frame padding under layer was spread over.

As padding was spread over encasing was manually sewn.

Finally prefabricated outer layer of hooding was spread over the softtop frame.

Door trimming panels were attached to the doors.

Body side trimming panels were attached to the dedicated places.

Restored headrests were attached to the seats.

Restored gauges and new steering wheel were installed in the cockpit.

New tank was still on the back order at supplier and we prepared old tank for temporary use until new tank is delivered.

As all main systems were installed on the car it was brought for the very first short ride in the yard.

We continued dashboard assembling works.

Functionality of restored cabriolet roof mechanism was tested.

Initial running gear adjustments were carried out before on-road tests were started.

Car was ready for test drive with number plates on. Weather conditions this year unfortunately were not supporting at the moment classic car test drive and we were forced to wait for climate conditions returning to habitual temperature.

In the meantime waiting for suitable weather conditions car was brought to Germany to take part in annual Technoclassica Essen.

Workmanship quality and retaining of authenticity was main topic touched in discussions by visitors from main Mercedes clubs in Germany and other countries. This was great possibility to get at opinion from business experts about our work and apply this expertise through the future projects.

Exposed car was attracting also classic car enthusiasts from the countries around the globe.

On return from exhibition assembling was continued. Mud guards were installed behind front wheels in the front wings.

New seat belts were fixed in place for the front seats. Body panels under the trim were removed to make necessary adaptations for rear seat belt installation. Seat belts were attached and all body panels returned to the place.

Dashboard central piece was adopted to fit radio unit. Antenna was attached to the windscreen.

To start run-in tests of various systems used fuel tank was adopted installing additional fuel filter in the line straight from the tank. This must prevent whole restored fuel supply system from possible dirt washed from the old tank surfaces.

During engine tests it was discovered, that several relays are not in proper working condition. All relays were checked as the new wiring harness. Unfortunately it was needed to change some important components of the electric system – like thermo and time switches for fuel supply system, warning relay and cold start switch.

Improper length of the front suspension arm rods was reason for healing of the car. We produced new rod to achieve correct ride height.

We self manufactured and installed hand brake cable guide to achieve hand brake adjustment.

During power plant tests it was noticed excessive oil leakage from the power steering pump. Pump was removed to eliminate defect.

It was checked position of the bright work around the cabriolet opening at the rear – no imperfections were noticed.

Radiator was removed and top part was repainted to achieve smooth appearance and suitable base for warning sticker application.

As weather conditions improved we started our driving trials to resolve all possible technical problems of the restored car. Each and any assembling unit had been carefully restored and tested before installation though we should ensure whole system together is working appropriately.

During trial period condition of all components was continuously monitored also looking about any engine, gearbox or power steering oil, as well as coolant, leakage.

During test drive it was noticed that reverse light switch has internal problem which sometimes creates shortcuts burning fuse feeding all control systems. Such switch was not available new from parts so we had to make adaptor for use of available suitable switch.

Supplied new exhaust pipes was not of completely correct shape adequate to 300SE and sometimes hit the body, so we had to remove whole exhaust piping and redo it to achieve proper fit avoiding contact of pipes with body on road bumps.

Exhaust emission tests and adjustments were carried out achieving satisfactory results.

As all improvements were introduced car again hit the road to prove that it is ready for trouble free use.

During test drive one of the aged cigar lighter contacts broke and we had to replace whole cigar lighter body.

As last was completed water tightness test to check function of new rubber seals and window adjustment accuracy.

Waiting was worth it – finally arrived almost a year ago ordered new fuel tank which was installed with no delay. We replaced at the same time all fuel filters.

As tests were finished car was prepared for delivery to the owner ready for the new life.