Mercedes Benz 190SL

I have not had a chance to work on the car for a few months. Now that time permits I have finished welding and grinding the plug weld spots of the left hand rear floor section. As it is hard work welding and grinding on your back, I looked at purchasing a Rotisserie, but could not justify the cost. Instead I shall proceed with the project in it's current manner.

I additionally decided to replace the left hand lower firewall as the right hand side came out nicely and since I do not have a streatcher and shirinker to hand, as the lower edge that joins to the front floor pan is curved. The rear floor sections are easier to weld in as there is more space. I have decided to remove the engine and turn the body on its side to aid welding, grinding and painting. On removing the engine by lowering the sub frame with the engine and gear box, the body could not be raised high enough to wheel out the complete unit. Instead the gear box will need to be removed from under the car. The engine can then be removed using a hoist from top, which should give me more room to wheel out the sub frame on its tyres. That job I have postponed until I am able to rally up a few more helping hands.

The factory spot welded the floor pans on to the main chassis sections. This was done before the outer body panels were welded on. As I do not have a single sided spot welder, I made good by punching holes on the edge of the floor pans where the spot welds would be and plug welded the holes. I additionally seam welded the inner side for added protection. The factory did seam weld at the rear portion where the floor curves upwards. I was concerned if my welds would hold up. Tests on a few weld spots proved my welds should hold up.

I plan on cleaning the surface rust by sanding and acid wash when all the welding is done.

Plan for next week is to have the right rear floor pan welded in. It does require a bit of cutting to make it fit. These cars were hand made and each panel was cut to shape before fit, so you can not just buy new panels from the factory and expect them to fit. The worst case I have come across was rear quarter panel, the edge that meets the boot lid on the left hand panel are a quarter of an inch too short. Mercedes Benz are aware of this mis-fit but suggest that the panel should be cut and a piece welded. One would not expect that kind of adjustment for panel fit.

This was the longest next week. More cutting and grinding was needed than I had thought to make this panel fit well. Once the rear sides were cut the panel welded nicely. This photo shows the welded panel which still requires finishing with the grinder. Progress this week was made on getting the front right hand floor pan ready for welding. This should be welded in by the end of this week. Luckly this panel does not need the cutting and grinding that the rear panels required.

All box sections like the rears were sealed with Wurth cavity wax after painting. This should safe guard against future rust.

Commenced working on front right floor pan. Easier to weld than the rears as no curves and bracekts in the way. The lower firewall welded excellently and fit was perfect. As this side has come out well I have decided to change the lefthand lower fire wall too, before welding in the last floor pan. I can see the end to the welding, as after the lefthand firewall, left fron floor just the seat support panels left.

Will need to decide soon the best way to turn the body over so that I can start the preparation work to paint the underneath.

Welded the last floor pan today. Looks good but hard work. Lots of grinding next under the floor pans. This should achieve an original finish like the factory spot weld. These were the most difficult parts to restore, as the floor pans need to be fit from underneath.

I would advise anyone doing the same job to invest in a rotisserie. This is one job that I would not like to do again. The cost of Chassis Tilter at £899 appears a lot to throw into one restoration but it would have saved a considerable amount of time.

The next project is the seat support boxes. Trial fit indicated that lost of adjustment, grinding and rebending will be need to make these fit. These were sourced from Jacksons Mercedes Benz main agent and I am suprised by the poor fit quality. It appears that these are not genuine parts but reproductions sourced from out side the dealership network.

Time for decisions on turning the car over so that I can start preparation of the underneath. I will let you know how I get on next time.

Above photos show trial fit of the seat support brackets. One lower seat pan was bent and needed straightening. The seat pan did not glide on its runners smoothly without much fabrication and adjustments to the seat support brackets.