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SLK 320 to SLK 500 Daves Project

222K views 3.3K replies 52 participants last post by  HambleSLK  
#1 · (Edited)
Hi Guys,

The Background :-

My last project, a low mileage W220 S Class which was wrecked by several local garages blowing up many modules with a power probe in an attempt to fix what turned out to be a faulty TCU :biglaugh:

I bought that Car around 3 years ago in a state of disassembly, just because someone in another local Garage said I'd never get it going 😉

It was running and MOT'd within 3 months despite having been stood in a Barn for 3 years and various bits were stripped out and just chucked in the Boot etc.

I then drove it around for a month or 2 and fell in love with it, so then decided to return it to concourse, I started off by stripping everything underneath and Undersealing (Schutzing) it, Waxoyling the cavities, etc and then time to start on the Bodywork. A little knock / scratch / scab here and there from standing in the Barn :(

I've also incorporated stuff like Android Multimedia, Facelift Lamps, Custom Exhaust and Mild Tune, Head Rest Screens with connection to Android, Full 4G Internet USB Charging Sockets etc etc.

It turned into almost a ground up restoration is now almost complete, should be totally finished after my 3 week Xmas Shutdown. and I'm already looking for the next project 😁

I currently have a V6 SLK in my Workshops, for Auto Box and ESP Problem, and after sorting the Gearbox and taking it for a test drive I thought hell, this is no "Hairdressers Convertible" >:D

Me want one to add to my MB Collection, (I currently own 3 roadworthy MB Cars) 😁

I found and put deposits on 2 Cars this week only to have my deposits returned by unscrupulous sellers because obviously they had had better offers.
These Cars were a fair way away from the remote area i live in, and they had both agreed to hold them for 2 weeks until I could get to see / buy / collect.

I'll have my SLK before long though, trying to do a deal on 1 of 2 possibles atm ;)

So, I got a load of work done today and had some time to play, hence out came the "Old" 2012 SDS and in came the R170 that I'm still waiting on a Yaw Sensor from MB Dealers.

I think it would be fair to say any of us who know Mercedes Cars will agree, by using a V6 Car as a base, dropping in a V8 from a mechanical perspective will be an absolute doddle using standard MB Parts ........................

Problems will arise when it comes to the Electronics !!

As others who have trodden this path have found, specifically with getting all the Electronics to talk to each other over CAN Bus, and also the Car builder needs to understand how the Immobilizer System works, and also the ramifications of the fact that the R170 uses DAS 2 Drive Authorisation (Mechanical Key Blade), and V8's such as W220 use DAS 3 (Infra Red Key / EIS).

I decided to look at compatibility with Electronics, Version Codings etc.

Here is my findings :-

Use the ECU from the V6 Car, now all Immo (DAS) issues are removed from the equation as well as things like the CAN Comms between ME and Instrument Cluster, ESP ABS TCU etc etc, because this V6 ECU is already matched to the Cars other Electronics !!

WHAT !! I hear you cry, but the V8 has 2 extra Injectors and Coils and being a 5.0 liter it will need different fuelling and timing etc that won't work !!

Oh yes it will, MB thoughtfully included other Engine Variants in the ECU's Programming, so all one has to do is use SDS to change the ECU Version Coding to M113 E50 🤓 EDIT :_ It isn't quite that simple see my findings in post #3, but still looking very do able !!

Transmission Control Unit Coding is a little harder, it isn't spelled out in plain English, when replacing these one needs a (not identical) but compatible part number TCU and copy the Coding from old TCU to replacement so yeah, one way or another Trans is no issue :|

I do have a sneaky feeling that by using the TCU that is on the V6 Car, (assuming one is keeping V6 Diff), then it's shift timing will be pretty close if not the same, and then Diff Ratios and Trans Gear Implausible issues will not be a problem.

I'm not certain if V6 and V8 Trannys have the same ratio Gearset, and I haven't checked the Diff Ratios either, will need to compare part numbers on WIS EPC, but none of this is an issue, by using the correct combination of parts and a little playing with Version Codings I am 101% certain that it will work 😁

If it turned into an issue I personally would fit a V6 Tranny Gearset into the V8 Trans, because that maybe has extra Clutches in it's packs to take the extra torque, or if one wishes to use the V8 TCU with V8 Trans and V8 Diff, then that should not create conflict either !!
I think for a Road Car the Diff from the V8 Car would be the one to use, again though there are a load of Codings that can be set in the ME ECU to alter Ratios and Tyre Sizes, and I believe that also applies to the TCU Coding from my experience with the S Class TCU. I expect I could get that info from MB as the TCU is a numerical Coding rather than Verbal on SDS Screen so I'd just need to know what number represents what (decode it) as it were ;)

Auto Transmissions used to be my Trade before I sold up in SE England and semi retired to NW Scotland.

ABS ESP and BAS require no version Coding, so although they Communicate to ME and probably TCU via CAN Bus they can be considered "Stand Alone" and therefore need no messing with.

Below are a load of pics from this afternoons session on SDS ;)

I'll be back soon with some more info when I've Compared the Wiring Plugs between a V8 ME 2.8 and the R170 V6 ME 2.8, my fingers are crossed right now 😁

Cheers Dave

Piccies :-
 

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#3,294 · (Edited)
Well, base coating this Inner Wing is a beast, mainly due to my laziness in as much as I don't have time to strip the front Grille and Lights etc out of the left front and remove a bunch of dash Panels and Modules so I can pull all the Wiring and bonnet Release Cable through the Bulkhead and inside the D15KOE !! Also not having much room makes it very hard to manouver the HVLP Gun to flick the areas with a nice even coat, so the technique here is I am pre- warming the area with a hot air gun, and then as soon as I have a coat on keep it warm with the HAG so it flashes off quick without saggy runs !!

Workshop is busy again from Tuesday and so close of play Friday saw me with 2/3rds of the repair area masked off and 3 coats of Base on it.

Yesterday we were out all day and evening.
The real issue here is if you are gonna paint an under-bonnet area ya really need to strip everything outta the way ;)

I don't recall ever painting anything with Red Metallic Pearl and boy this Rioja Red Base Coat is a learning curve .....................

It is extremely opaque, meaning that when painting the primered areas and overlapping the existing base, the colour comes out a little darker over the old basecoat :(
So I have just given it 2 more coats, it is OK.

You can't see the darker areas I'm waffling on about it in these photos, what you are seeing in the pictures here is what I love about this colour as contour angles and lighting reflections change it shifts from a darker red to a "goldy dark orangey" colour ............

Hood Automotive lighting Automotive exterior Wood Bumper


It is as good as it's gonna get now so I'm leaving it to go hard enough then later today I will remove some of the forward end masking to relocate the Wiring and then I will have more freedom to move the rearward (bulkhead) end of that wiring and do that last wee bit down by the Bulkhead !!

This is not too much of a biggie, because when all the bits are back in you won't see most of it remember the pic in post #3,276 when it was assembled last week ....


The whole idea is that the grey primer smacks ya straight in the teeth as soon as ya open the bonnet, where now once it's all back together and one opens the Bonnet it will require a bit of looking to confirm that it actually has had the Inner Wing Wheelarch areas done ................

So back to my pragmatic ethos with the D15KOE repair works, which is to create a functional, reliable VGC tidy looking vehicle, and not a concours resto by any means ;)

So in a while I'm off to start re masking and chuck some Basecoat at the last wee bitty of this repair.
Tomorrow morning I'll hopefully be able to de-mask everything and then fit it all up and forget this area for a long while.

When I do the right side, probably next year I think I might do that area with a couple of rattle cans, as you see even less due to all the clutter, the Battery and Jack etc are under that big black cover, fuse and relay box behind that, then the brake booster and master cylinder ....

Trunk Car Motor vehicle Automotive exterior Gas


And final update on "Dave Fleet" the 265 / 35 x 18 Falkens turned up whilst we were out yesterday, I'll likely fit them up a few days before the W212 AMG Wagons MOT which is booked for 9th March, so may as well get a bit more mileage outta the cream crackered ZV7's :ROFLMAO:

We managed to stick another 200+ miles on the Car yesterday, they are still just about legal :p
Car is once again driving superbly atm, and I managed to avoid all the bloomin' pot holes along the "North Road" yesterday :D :D :D,

After Strathpeffer, Black Isle and then Inverness for lunch we came back via the A87 which is in much better condition. Trouble is if we also went that route to first stop Strathpeffer it would then add approx 60 more miles instead of the round trip.............
I'm not sure what would be dearer, fuel and regular wear and tear or just repairing pothole damages as and when, or simply doing as we have been and chucking more fuel money at the journey by taking D15KOE who, with his upgraded Suspension and the big 10 ply tyres simply doesn't notice the Pot Holes, it somewhat feels like you mighta / perhaps / just possibly have run over a matchbox :ROFLMAO:
 
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#3,295 · (Edited)
Well that's the inner wing job all finished with the repaired area now the same colour as the rest of the D15KOE.
Busy week ahead now with a ton of work in !!

It has achieved the objectives which are that the Inner Wheel-arch is now solid, rust free and grey Epoxy Primer isn't slapping me in the moosh every time I open the Bonnet ....

Vehicle Hood Motor vehicle Car Automotive design


Motor vehicle Electrical wiring Gas Auto part Wire


Of course it does highlight 2 more jobs that will get done eventually, probably at Chassis swap time as it will be much easier when it's on the lift with no Axles, Chassis and Engine / Gearbox in there .........

Namely the "Dogs Breakfast" sound deadening on the Bulkhead needs re furbing either with some black upholstery paint or just strip the paint off it and leave it grey !!
Even more so, those Brake Pipes .................

Those ARRRRRRRGH !!!! Brake Pipes that the previous inepts fabricated and fitted before I bought the D15KOE, clearly the ahem cough cough "mechanic" that did that job had absolutely no pride in the work he does :( 😭
They are of course rust free and functional, and as I've run outta time on this round of D15KOE works, they will have to remain for now, but will get done later this year when I got time, as I have carefully taken the original factory ones off "Oxford" (the breaker Discovery 2) to use as patterns so I can do the job properly (y)

MOT next Monday :)
 
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#3,298 · (Edited)
I came across this earlier during a discussion with a buddy about Mercedes M112 / M113 Kompressor Blower Bearings ;)

This guy really knows how to build a motor (y)

So what with me having had a bit of "live" experience with an awesome Hemi many years ago that was in my old buddy John's 1941 all steel Willys Coupe, a car that has won trophies everywhere it went I just thought I'd share it with y'all (y)

Anyways, this one is just awesome, well worth a watch ....

 
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#3,300 ·
less air entering the engine equals less power produced
Kind of almost, less Air = less fuel can be burned before it goes rich and loses power, the clever bit is those carbs which are connected to the Boost Pressure and thus they don't need re jetting each time they swap pulleys, because more boost pressure simply increases the amount of Fuel getting chucked down it :D

I guess the modern equivalent is the 3 bar MAP sensor on EFI Motors.

Johns Hemi in the Willys originally ran Hilbourn Alky set up when it was first built, it was on Petrol last time I saw it in UK as after he ran low 9's with it he stopped drag racing it in UK. That was roughly 21 years ago when he emigrated and took it to Perth, Aussie wiv him. He sold it around 10 years ago after racing it again, got a record or 2 out there, but they wouldn't let him Road register it due to it having Spaceframe Chassis 😭 ....

 
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#3,301 ·
/\ /\ /\ I see a picture of one of my own builds, my SBC V8 Fiat 500 in that gaggle of FB Pictures within the Magazine Article about John's Willys, IIRC that show was in Belgium, (may have been Holland), not sure now, it seems like a lifetime ago ;)
 
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#3,307 ·
Here's a couple more shots of some of the Detail ....

Early on in the construction, Chassis etc now all up and running with some old seat fitted so we could shake it down around the Industrial Estate, shots taken outside my old Transmission Firm, the Body was held in place with just 4 Bolts and some locator dowels, it took about 10 mins to unplug some wiring and unbolt and lift the Shell off the Chassis for maintenance work ;) ....
Wheel Tire Automotive tire Vehicle Car



Tire Wheel Vehicle Car Automotive lighting


Window Vehicle Hood Motor vehicle Car


Vehicle Motor vehicle Speedometer Hood Automotive design
 
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#3,314 ·
D15KOE has passed his MOT Test with flying colours today, only the 1 advisory this year, Surface Corrosion from middle to front of chassis but not significantly reducing structural strength !! That will almost certainly be a given on most vehicles, especially an original Chassied 24 year old Land Rover that has lived in NW Highlands for a fair few years now. ;)

Tester agrees with me that the Chassis will likely still be OK for next test, so depending on how many of my other Car and Building works projects get finished between now and December he may get another year on this Chassis before I replace it, so hopefully that could run to December 2024 !!

I will externally re waxoyl that front half again this summer, if I schutzed it I wouldn't even get that advisory, but tbh I'd rather just clear waxoyl it then I can still see what's going on and monitor the surface rust easily ;)

Time for his Oil Change and enjoy driving D15KOE for the next 12 months (y)
 
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#3,316 ·
It can be, but the guy I use really knows his job, and as I use him all the time for the last 16 years now we both know how each other work, and the standards he expects (y)
 
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#3,317 · (Edited)
Rangey Rover going home this arvo, total bill £3032 and some pennies :ROFLMAO: Still it is driving sweet as a nut now ;)

W212 AMG E Class Wagon MOT this afternoon .............. Should be fine was checked about 3 weeks ago and a couple of jobs done about the same time as D15KOE :)

The Falken rear Tyres have scrubbed in now, and absolutely no difference in handling whatsoever, if anything the road noise is noticeably quieter ;)

I will fit the same Falkens to the front later in the year when I've wrecked the Avons, they are approx £100 each so a bit cheaper than the wider / lower profile rears :D
 
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#3,318 · (Edited)
I feel strangely fortunate that we do not have the whole MOT process here in Florida. Other states do have varying inspections for emissions and safety. I was a licensed inspector in Texas many years ago, and that amounted more to a tax on the vehicle owners than an actual safety test.
 
#3,322 ·
As was our "smog" emissions test. Something like 95% of the cars that HAD to go through passed. So many complained, that tax was cancelled.

The worst part was heavy trucks and buses had to go yearly. Totally ineffective as we regularly followed them breathing the black fumes they pumped out.

The only losers were the shops that had to spend $100,000 on testing equipment that was now scrap metal.
 
#3,319 ·
Passed wiv flying colours, no advisories at all, but he did verbally point out that the left front rim has a slight depression in the inner bead / rim edge which is since I hit a Pot hole, and after that I have noticed a very slight harmonic in the Car at driving ban ++++ speeds ;)

It's gonna need new front Tyres before too long, so as I got 2 spare front rims I'll get one painted up to match t'others soon ;) These W212 AMG rims are very prone to this kinda damage on the UK war-zone roads, because they have large offsets, but usually they don't crack, and so I will get that front one straightened, un damaged fronts are harder to find than rears that are straight due to kerbing when parking, they just need a re paint cos the lacquer peels on 'em ;)
 
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#3,320 ·
BTW @nemiro your Crossfire linky disappeared, 🕵️‍♂️ but I can't buy my new Drift Car project yet until I finish and sell the Silver R170 so won't be for a fair while yet ;)
 
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#3,323 ·
They did away with emissions testing in Florida (and many other states) for the exact same reason. In relation to the big picture on total vehicle life cycle emissions, the most environmentally friendly thing a citizen can do is to keep an old car running for as long as possible. Even if a new car is cleaner at the exhaust pipe, scrapping a car, melting it down and turning it into a new car uses much more fossil fuel and puts way more pollution into the environment than just keeping an old clunker going.
 
#3,326 · (Edited)
Yes, likely next year as I need to free up a space by finishing and selling the silver V6 R170.

Cheap form of UK Motorsport, great fun, and no FIA involvement (which killed stage rallying at club level) due to stupid rules that make it way too expensive at Club level !!

Just one example, clubby guys might use their rally Car 3 -4 times a year, but after 5 years, regardless of condition, the seats and harnesses have to be replaced, and those are "special ones" that must have FIA approval etc etc yak yak yak :( That was the point when I sold my 24V Cosworth 4x4 Ford Puma Stage Rally Car, (still with mint Seats and Belts but outta date), and bought my blue SLK.

Yup, I first thought of using my silver SLK and fitting with a V8, but 2 things ....

Roof and mech is very heavy, lot of hassle to just weld it shut properly and remove all the other bits.

Also, whilst some guys use convertibles at some UK Venues they are not allowed by at least 2 of the localish tracks I will be using for safety reasons.

So then I was going to use a W203 C Class Coupe V6 ............... I found one locally, took a trailer but it turned out to be a basket case, haven't found any more V6 320 ones at sensible money in UK .......................

Then I did research and found that a Crossfire 3.2 V6 Coupe with 6 speed MT will be perfect, they are coming up now fairly cheap, the ideal one will be with an Immobiliser (DAS - RF (SKREEM) module dead or poss V6 Engine dead for peanuts.
Body doesn't have to be mint either as it will likely get an unusual and bright livery, so no big dents, rot etc but don't mind some scratches / colour mismatches !!

Idea is fully stripped of all Interior / Boot Trim, 2 Bucket Seats, Full Harnesses, Full Roll Cage with Door Bars, LSD (maybe even a welded) 3.27 stock V6 Diff, custom LCD Dash Cluster, ABS / ESP removed, added Camber, added Steering lock, reduced Ackerman, etc and plop in a lively M113 V8. Minimise / simplify wiring to the point of "it's road legal", and now I have a car that can be taken on road for a blast but primarily trailered to Drifting events :D :D :D
 
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#3,330 ·
WOW, thanks for that (y)

Being the age I'm at now i do sometimes doubt myself, but thats good to hear that a well educated and much younger mind has come up with the same conclusions as myself and a few other of my fossil colleagues who researched it a couple of years back ;)
 
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#3,331 ·
EV there is all the pollution and energy involved in Batteries, which are absolutely knackered by year 5 so need replacement

That an FIA rule Dave?

The idea of EV still needs work. For now I see it as a concept being developed by the owners pockets.
We live in a throw away culture. Lucky if a phone is still supported at 5 years & just how many ecos have the latest phone.
 
#3,333 · (Edited)
EV there is all the pollution and energy involved in Batteries, which are absolutely knackered by year 5 so need replacement

That an FIA rule Dave?
:ROFLMAO:

Nope, I have seen and heard of a fair few EV's up here that have got down to 75 miles or less range inside 5 years.

One of my fleet owner customers friends who lives on Skye bought an EQ last year about 50% of cost price is on finance from MB Approved Used Cars at a southern Scotland main dealership.

That car was at the time of his purchase 4.5 years old, 70k miles. He'd had it about 6 months (another 3 k miles) when the battery pack failed completely, dash like a christmas tree !!
Car recovered back to the selling dealership. At this point MB quoted him well north of 16k to replace it, which has effectively written the car off !!

Guy is a working man, simply cannot afford it, Finance company have ruled he still gotta pay for it !! He bought this car with an MB approved used car Warranty, who say battery pack is not covered under warranty, because the small print hidden somewhere in the MB documentation says that the life span of the battery pack is 5 years, and sales staff are trained to tell buyers that !!

MB sales folks did not tell the guy that when he bought it or he simply wouldn't have, he is adamant, and he is an honest man !!

He is now driving around in a 15 year old BMW which has over 300k miles on, its tidy and runs well, it is one of the fleet owners well maintained diesel cars which he gave to his friend so he can get to work and support his family whilst still being screwed over to pay for the ticking time bomb he bought from the oh so honest dealership !!
 
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