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W202 Wagon build thread - *NOW OM606*
MartinB Offline
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#51
RE: W202 Wagon build thread - *NOW OM606*
I bought W220 S600 Calipers for my W210. These are for 345mm discs Wink
02-09-2016, 05:23 PM
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Hario' Offline
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Location: SW London
#52
RE: W202 Wagon build thread - *NOW OM606*
(02-09-2016, 05:23 PM)MartinB Wrote: I bought W220 S600 Calipers for my W210. These are for 345mm discs Wink

Yep, the S500 ones are 330mm but and loads cheaper here in UK anyway



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
02-10-2016, 07:51 AM
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MartinB Offline
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#53
RE: W202 Wagon build thread - *NOW OM606*
I bought both for about 1500 CZK = 55,5 € = 43 GBP Smile
02-10-2016, 06:13 PM
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Hario' Offline
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#54
RE: W202 Wagon build thread - *NOW OM606*
(02-10-2016, 06:13 PM)MartinB Wrote: I bought both for about 1500 CZK = 55,5 € = 43 GBP Smile

I found out W203 C32 discs are 345mm and correct offset for W202 knuckles by the way.

But the calliper will still need the 3 or 4mm hardened washer spacers of course.

Regarding the hoses, the calliper end needs to be a 20 degree banjo hose fitting, to point in the right direction, and the hose needs to be 100mm longer than the standard item. But I still haven't worked out what the fitting is on the car end yet.



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
02-12-2016, 05:22 AM
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MartinB Offline
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#55
RE: W202 Wagon build thread - *NOW OM606*
Yes, you are right 345×30 (S600 has 32mm). C30/32/55 amg have drilled rotors. Now I have to find some calipers for rear axle - for 300×22 mm discs.
02-12-2016, 09:33 AM
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Hario' Offline
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#56
RE: W202 Wagon build thread - *NOW OM606*
(02-12-2016, 09:33 AM)MartinB Wrote: Yes, you are right 345×30 (S600 has 32mm). C30/32/55 amg have drilled rotors. Now I have to find some calipers for rear axle - for 300×22 mm discs.

ML 2-pistons are very cheap here, I'm gona buy one and try it



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
02-16-2016, 12:10 PM
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MartinB Offline
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#57
RE: W202 Wagon build thread - *NOW OM606*
Dont buy them! They are not same. Don´t fit.
02-17-2016, 02:49 PM
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Hario' Offline
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#58
RE: W202 Wagon build thread - *NOW OM606*
(02-17-2016, 02:49 PM)MartinB Wrote: Dont buy them! They are not same. Don´t fit.

Ok thanks, you know of any more S600 callipers? I'll pay a handling charge..



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
02-18-2016, 10:30 AM
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MartinB Offline
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#59
RE: W202 Wagon build thread - *NOW OM606*
No, sorry. It was little bit luck. Here was one S600 for spare parts. When I have time, I will take a photo of difference between S600 and ML calipers. S600 needs only washers to fit. Do you know the fact, that then you can use only 17"+ wheels ?
02-18-2016, 03:32 PM
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Hario' Offline
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#60
RE: W202 Wagon build thread - *NOW OM606*
(02-18-2016, 03:32 PM)MartinB Wrote: No, sorry. It was little bit luck. Here was one S600 for spare parts. When I have time, I will take a photo of difference between S600 and ML calipers. S600 needs only washers to fit. Do you know the fact, that then you can use only 17"+ wheels ?

Yes man 18" minimum with 345mm rotors, 330mm will fit 17"s.

Ok I see S600 calipers are quite cheap here also, I guess not many people own a S600 and go on ebay to get spares for it haha.

What are you thinking for hard washers? I can't find any off the shelf at 3mm thickness so going to ask a machinist for a quote. I'll get a patch if theyre cheap.



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
02-19-2016, 06:38 AM
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MartinB Offline
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#61
RE: W202 Wagon build thread - *NOW OM606*
345mm will fit also 17" Wink

C30/32/55 has original 17" wheels
ML - 17" also
02-19-2016, 08:42 AM
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Hario' Offline
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#62
RE: W202 Wagon build thread - *NOW OM606*
[Image: rotors1.jpg]

[Image: rotors2.jpg]

Got someeee.

W203 C32 AMG 345mm rotors.

W220 S600 limo calipers.

Working on home built hoses this week



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
03-10-2016, 07:02 AM
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Hario' Offline
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#63
RE: W202 Wagon build thread - *NOW OM606*
DIY air/fluid ATF cooler install, I definitely don't get any points for my inner wing hole sawing skills.

[Image: F81F2A37-F8D6-453E-B73A-73E06FA55C8B.jpg]

[Image: 5CE96EE3-BA28-4739-950E-0723C419DE0A.jpg]

[Image: atf3.jpg]

[Image: atf2.jpg]

[Image: atf1.jpg]


[Image: atf8.jpg]

[Image: atf9.jpg]
Do I need stone protection for the cooler core??

Also I'm thinking ATF cooler fan always on with ignition, is a temp switch really needed? Say 80 degrees Celsius..

Beers, H.



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 03-10-2016, 07:27 AM by Hario'.)
03-10-2016, 07:20 AM
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Hario' Offline
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#64
RE: W202 Wagon build thread - *NOW OM606*
Made some turbo space:

before/after w210 header tank swap..

[Image: atf4.jpg]

[Image: header%20tank%20relocate.jpg]



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 03-10-2016, 08:38 AM by Hario'.)
03-10-2016, 08:35 AM
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Hario' Offline
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#65
RE: W202 Wagon build thread - *NOW OM606*
I've found out the petrol 202 chassis has a lift pump mounted on a bracket under the tank, so I'm thinking of using the mount for a lift pump on my diesel chassis, need to see if it has the mounting lugs for a bolt on swap, (I hope so).



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
04-09-2016, 07:19 AM
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Hario' Offline
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#66
RE: W202 Wagon build thread - *NOW OM606*
(02-12-2016, 09:33 AM)MartinB Wrote: Yes, you are right 345×30 (S600 has 32mm). C30/32/55 amg have drilled rotors. Now I have to find some calipers for rear axle - for 300×22 mm discs.

Hey man which rear 300mm rotors and calipers did you get? I'm working on the back end now too.

Beers



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
04-26-2016, 12:49 PM
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MartinB Offline
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#67
RE: W202 Wagon build thread - *NOW OM606*
I bought W220 S500 rear calipers. Not tested yet :-)
04-27-2016, 03:28 AM
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Hario' Offline
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#68
RE: W202 Wagon build thread - *NOW OM606*
(04-27-2016, 03:28 AM)MartinB Wrote: I bought W220 S500 rear calipers. Not tested yet :-)

As in don't know if they fit? Ok sweet ill hope for good news!

W220 rear is 330 vented or not, and 58mm disc height (202 is 55.5). So assuming the 3mm offset works with the 220 caliper on the 202 hub we are good to go.

Can get 300mm rears discs on low power w220s so that might work, poss with the w202 amg disc (also 300mm) but again 3mm offset difference.

Gona try it and see as they say



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 04-27-2016, 11:32 AM by Hario'.)
04-27-2016, 06:34 AM
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MartinB Offline
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#69
RE: W202 Wagon build thread - *NOW OM606*
Today I measured little bit. I think they will fit. Maybe with some 3mm spacers will be ok. Discs from E55/C32/C43....
04-27-2016, 04:59 PM
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Hario' Offline
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#70
RE: W202 Wagon build thread - *NOW OM606*
Trial fit fronts, internet source banjo required on fronts is bollox. Stock convex cone and +50mm on the length is all that is needed, got to redo the hoses..

5mm tool steel spacers work good though, calliper is 5mm from wheel spoke inner face..

[Image: brakes%202.jpg]

[Image: brakes%201.jpg]



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
05-23-2016, 04:52 AM
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Hario' Offline
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#71
RE: W202 Wagon build thread - *NOW OM606*
3 out of the 4 jacking points and associated outer sill areas were borked.. (All good now).

Happy this welding is finally out the way so I can get onto the fun stuff..

Note the quality of some areas of the welding is due to using 0.8mm wire, 1.2mm plate, and 10.0 beers..

[Image: 2_9.jpg]

[Image: 3_8.jpg]

[Image: 7.jpg]

[Image: 6_1.jpg]



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 05-23-2016, 06:03 AM by Hario'.)
05-23-2016, 06:01 AM
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North_Star Offline
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#72
RE: W202 Wagon build thread - *NOW OM606*
Truly outstanding build here!
05-23-2016, 03:18 PM
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Hario' Offline
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Location: SW London
#73
RE: W202 Wagon build thread - *NOW OM606*
(04-27-2016, 03:28 AM)MartinB Wrote: I bought W220 S500 rear calipers. Not tested yet :-)

I bought an S500 rear calliper to trial fit also, bolt spacing looks good, I think more like 5-8mm spacer maybe.

Couldn't get the seized 16mm calliper bolts loose though! ARB drop link won't let me get a ratchet on, more beer needed...



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
06-18-2016, 06:16 PM
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Hario' Offline
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#74
RE: W202 Wagon build thread - *NOW OM606*
(04-27-2016, 04:59 PM)MartinB Wrote: Today I measured little bit. I think they will fit. Maybe with some 3mm spacers will be ok. Discs from E55/C32/C43....

W203 C55 rear rotors bought 300x22 and 55mm height. Got S500 rear calliper to try and make it work.

Fronts now on, had to peel my face off the windscreen first try..

[Image: brakes%203.jpg]



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
07-13-2016, 07:43 AM
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Hario' Offline
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Posts: 793
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Location: SW London
#75
RE: W202 Wagon build thread - *NOW OM606*
Got LP turbo, need to mock up the HP outlet to LP inlet pipework and check see if it fits under the bonnet. Laptop for scale..

[Image: hx52.jpg]



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 07-13-2016, 07:50 AM by Hario'.)
07-13-2016, 07:49 AM
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Hario' Offline
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#76
RE: W202 Wagon build thread - *NOW OM606*
Rears replaced with W203 C36 callipers and rotors, hoses made with Goodrich hose and re-buildable fittings.

[Image: discs1_1.jpg]

[Image: 20161003_102159.jpg]

[Image: 20161008_150425.jpg]

Forgot to paint the dam backing plates..



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
10-23-2016, 01:44 PM
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Hario' Offline
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Location: SW London
#77
RE: W202 Wagon build thread - *NOW OM606*
Replaced the DV seals and washers, still idles like shit..

Going to get new nozzles and rebuild the injectors, HughF on here has a pop tester so we can do it ourselves, thinking of going for 150 bar pop pressure, in anticipation of fitting a build pump once I've sorted the chassis. Has anybody done that with the stock 6mm EDC pump before? IE will it run ok or need timing adjusting because of the higher pop pressure?

Shall I go for Monark ones or stock Bosh nozzles? Any input appreciated!

[Image: dv1.jpg]

Beers, H..



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 10-23-2016, 01:49 PM by Hario'.)
10-23-2016, 01:47 PM
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Hario' Offline
C300TD Wagon (W202)
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Location: SW London
#78
RE: W202 Wagon build thread - *NOW OM606*
I decided to go for 3 x 2-1 merges, then a 3-1 merge at the turbo, for space saving and less pipes to weld!

That straight pipe I bought for the merge is such heavy gauge it takes ages to cut, and now I've got to chop a big hole in the side of it for the WG, dam..

Excuse the welding, I will get one of my pro friends to MIG/TIG over the joints later.

[Image: 20160924_174222.jpg]

[Image: 20160925_201643.jpg]

[Image: 20160926_200912.jpg]

The bottom runner in the last photo will not give me good DP clearance so I will re-do it much closer to the block..

All good fun though



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 10-23-2016, 02:18 PM by Hario'.)
10-23-2016, 02:15 PM
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Mr_Robs Offline
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#79
RE: W202 Wagon build thread - *NOW OM606*
Good to see some progress mate. I still havent a fucking clue what im doing about brakes. I have 16's and some 400e calipers but i dont think they will be enough...

Going with an autobox for now that should make its way over here in a few weeks from Amar. Still so much shit to buy.

I still need to grab one of those 210 tanks myself too.
10-23-2016, 03:41 PM
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addi.bigg Offline
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#80
RE: W202 Wagon build thread - *NOW OM606*
(10-23-2016, 01:47 PM)Hario Wrote: Replaced the DV seals and washers, still idles like shit..

Going to get new nozzles and rebuild the injectors, HughF on here has a pop tester so we can do it ourselves, thinking of going for 150 bar pop pressure, in anticipation of fitting a build pump once I've sorted the chassis. Has anybody done that with the stock 6mm EDC pump before? IE will it run ok or need timing adjusting because of the higher pop pressure?

Shall I go for Monark ones or stock Bosh nozzles? Any input appreciated!

[Image: dv1.jpg]

Beers, H..

As far as i've heard Bosch ones, also the OE Merc Boschs are coming from India with a questionnable quality.
10-24-2016, 01:31 AM
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Tobulus Offline
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#81
RE: W202 Wagon build thread - *NOW OM606*
They are coming from India, but they are as good as the ones in the older days. Its a question of quality control, not of the country they are made in. The Bosch nozzles are still the best you can get, but they are by far the most expensive. Thats why I dont use them, there are good alternatives on the market, for example Henzo nozzles.
10-25-2016, 12:44 PM
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Hario' Offline
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Location: SW London
#82
RE: W202 Wagon build thread - *NOW OM606*
(10-23-2016, 03:41 PM)Mr_Robs Wrote: Good to see some progress mate. I still havent a fucking clue what im doing about brakes. I have 16's and some 400e calipers but i dont think they will be enough...

Going with an autobox for now that should make its way over here in a few weeks from Amar. Still so much shit to buy.

I still need to grab one of those 210 tanks myself too.

210 coolant header tank?

I think I've got one you can have!



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
10-26-2016, 02:05 PM
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Hario' Offline
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Posts: 793
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Location: SW London
#83
RE: W202 Wagon build thread - *NOW OM606*
During a waterpump swap, I also invented a way to remove the visco coupling with out the special and expensive Mercedes tools, there are 3 tools you are supposed to buy for this exercise. I just used a pipe wrench, monkey wrench? English name for that thing.. As below, works well and cracked the bolt easily, I just wrapped the jaws in electrical tape to save the pulley & belt from le damage.

[Image: visco%20tool%20removal.jpg]



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
01-11-2017, 04:28 PM
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Hario' Offline
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Location: SW London
#84
RE: W202 Wagon build thread - *NOW OM606*
Parts.. Thanks Hendrik / hents99!

[Image: precombustion%20chambers%20and%20injectors.jpg]



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
01-11-2017, 04:37 PM
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Hario' Offline
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Posts: 793
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Location: SW London
#85
RE: W202 Wagon build thread - *NOW OM606*
Bought an Oxford Welders Atomic 160 ( old and British Tongue , with big clunky buttons haha), and converted it to euro torch because euro torch and did some patching

[Image: welder2.jpg]

[Image: welder1.jpg]

[Image: welder3.jpg]



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 01-11-2017, 04:43 PM by Hario'.)
01-11-2017, 04:42 PM
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Hario' Offline
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#86
RE: W202 Wagon build thread - *NOW OM606*
Bit boring but I made some rust repair progress, very satisfying, other inner rear arch to do then the weld-a-thon is complete

[Image: wing2.jpg]

[Image: rear%20arch%20patch%201.jpg]

[Image: rear%20arch%20patch%202.jpg]



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 01-11-2017, 04:51 PM by Hario'.)
01-11-2017, 04:50 PM
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charlysays Offline
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#87
RE: W202 Wagon build thread - *NOW OM606*
(01-11-2017, 04:50 PM)Hario Wrote: Bit boring but I made some rust repair progress, very satisfying, other inner rear arch to do then the weld-a-thon is complete

[Image: wing2.jpg]

[Image: rear%20arch%20patch%201.jpg]

[Image: rear%20arch%20patch%202.jpg]

Well done. Once I started digging around on mine there were a lot of holes in the inner front wings. Worst bit was up at the top, in the channel where all the wiring runs just below the outer wing mounting rail. But anywhere where there was one of those weld studs for the inner arch liners there was a good chance of a hole.
You can buy M6 weld studs off ebay and plug weld them on, then drill out the black plastic nuts a bit bigger and it works.
01-12-2017, 07:08 AM
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Hario' Offline
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#88
RE: W202 Wagon build thread - *NOW OM606*
(01-12-2017, 07:08 AM)charlysays Wrote:
(01-11-2017, 04:50 PM)Hario Wrote: Bit boring but I made some rust repair progress, very satisfying, other inner rear arch to do then the weld-a-thon is complete

Well done. Once I started digging around on mine there were a lot of holes in the inner front wings. Worst bit was up at the top, in the channel where all the wiring runs just below the outer wing mounting rail. But anywhere where there was one of those weld studs for the inner arch liners there was a good chance of a hole.
You can buy M6 weld studs off ebay and plug weld them on, then drill out the black plastic nuts a bit bigger and it works.

Thanks, the front of mine is completely fine, I've had all the front panels off, it just has very localised rust to all 4 jacking points, NS and OS rear floor and the arches as above. It's started at the seams and progressed about 2-4" in every direction, fortunately I've caught it in time. I've used 3 cans of waxoil so far..



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
01-12-2017, 01:40 PM
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charlysays Offline
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#89
RE: W202 Wagon build thread - *NOW OM606*
(01-12-2017, 01:40 PM)Hario Wrote:
(01-12-2017, 07:08 AM)charlysays Wrote:
(01-11-2017, 04:50 PM)Hario Wrote: Bit boring but I made some rust repair progress, very satisfying, other inner rear arch to do then the weld-a-thon is complete

Well done. Once I started digging around on mine there were a lot of holes in the inner front wings. Worst bit was up at the top, in the channel where all the wiring runs just below the outer wing mounting rail. But anywhere where there was one of those weld studs for the inner arch liners there was a good chance of a hole.
You can buy M6 weld studs off ebay and plug weld them on, then drill out the black plastic nuts a bit bigger and it works.

Thanks, the front of mine is completely fine, I've had all the front panels off, it just has very localised rust to all 4 jacking points, NS and OS rear floor and the arches as above. It's started at the seams and progressed about 2-4" in every direction, fortunately I've caught it in time. I've used 3 cans of waxoil so far..

It's weird how they rust in different very ways... all the jacking points on mine were perfect. There was some nasty random surface rust around some of the holes in the lower sill where the big round cover clips push in. Bit of welding on the lower rear quarters behind the bumper. Both front perches had rotted out at the top to some degree. All in all really not bad for a 20 year old original car with history of crash damage. Mileage definitely plays a role. Lower mileage cars tend to be less rusty in general as the crap paint hasn't had such a beating!
01-16-2017, 06:24 AM
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