1997 Mercedes e55 estate - a bit crashed, but super cheap!
Discussion
The background... Currently driving an e430 estate, and bought it as a stop-gap for the UK-Germany commute. I bought it because it was 500 quid and once I threw the LPG kit on it (there is a thread on here somewhere about that), it became cheaper than my Passat TDi to run. Far more comfortable too. However, I really wanted an e55, but they still command good money and are just too far out of reach. I told a mate who worked at a Merc main dealer that I was after a cheapish e55 estate (probably needing some work), but being fairly rare cars, it was really just a speculative heads up. Within 24 hours, he phoned me back to say he'd found one. No idea how, but it not the first time he's done that!
The w210 e55 was quite a thing in it's day, as it looks the same as all the other w210's that came off the production line, but they are almost entirely hand built by AMG. One man built each engine, then put his name on it. It is not silly quick by today's standards, but with 350bhp and 400ft/lb, it is no slouch. Really rather looking forward to getting it out there...
So, it's a 1997 car, it is a Cat C needing VIC, and it has some damage. However, these sell for £6-8k when in good condition, I paid less than a third of that. Time to play...
First view
Not too bad!
Yup, correct engine
Minty interior. 87k on the clock. Very nice! It's a 7 seater too...
Perfect seats with no bolster wear
And the damage
Front corner a bit bent, but nothing structural
Front missing
And the worst bit
A-pillar not bent though, and the door still aligns perfectly.
Story goes that the guy lost it and hit a lamppost. The guy I bought it from took it and started fixing it up, new suspension and wheel, although I suspect he did this mostly so he could move it around the workshop. He then ran out of time and/or interest to get it finished. So, it is now mine!
He presented me with the keys. This photo speaks the truth
Firstly, lets get it home...
My trusty e430 wagon doing sterling service as always, 600 mile round trip. Towed at 50mph as if nothing was behind it Yes yes, possibly a trifle over weight, but it pulled like it wasn't there. Such great towing cars!
9.7 litres and 16 cylinders in this pic
On the way home, I stopped in at another e55 (saloon) that was being broken for spares. Getting involved with a 12" petrol cutter the owner cut out the bits that are bent on mine. Took loads of spares inc. mint front wing and also got a spare set of front discs and callipers because... well, they are bloody expensive! Front discs are bespoke to the e55 and cost 600 quid a pair! These ones are better than what's on the car, so I will just reface them on the lathe at some point. All in £170 Result!
And home safe
Front bit of the repair panel is rather rusty, but that can be fixed later. Note, regulation custard creams on air box for grinder mission sustenance.
Damn, it took quite a knock here!
Lets have a look at this damage in more detail
It looks like someone has already been at this with a hammer. Hmmm.
Out with the grinder...
Cut as much bent bits out as possible.
And shape the spare part to fit. Measure twice, cut once!
Mock up with an old rusty wing.
Yup, panel gaps look about correct.
But first, need to cut out the rust in the repair panel.
Fixed!
Quick interlude to get rid of an old MX5 shell. Also got rid of my lovely '77 323 (orange bit of this photo). Pity, but it was just too far gone
Forgot to get a photo of it's last journey...
For most of the repair, I will overlap the metal slightly to get a good weld, but the front bumper bar really needs a bit more strength than that and would look odd if overlapped. Therefore I will butt weld it, but with some strengthening behind.
So weld in this plate with some spots
Then weld the panel in.
The gap between the two panels there is deliberate enabling a good strong weld between the three bits of metal.
And finally, stitch it all in.
I now used the old wing to ensure everything still lines up correctly as I am welding. By cutting this hole, I can weld this seam without fear of it warping or moving out of shape.
Close up. Approx 5mm overlap to get a nice clean weld.
Once all done, they will all be coated in seam sealer, then lots of rustproofing!
So this is after about 3 evenings work. Unfortunately I ran out of welding gas, so had to to stop for the evening. Will update as I do more, but later, I get to play with this!
Borrowed from a mate, this will allow me to pull out the damaged outrigger as much as possible before then cutting out the damaged section and replacing it.
More soon
Comments, criticism, advice etc always welcome. I am just a hobbyist, and although quite confident at repairing rusty dross, never had a go at crash repair before, and just sort of making it up as I go. Therefore, I would be interested in any advice, especially if I could do anything better! Cheers!
The w210 e55 was quite a thing in it's day, as it looks the same as all the other w210's that came off the production line, but they are almost entirely hand built by AMG. One man built each engine, then put his name on it. It is not silly quick by today's standards, but with 350bhp and 400ft/lb, it is no slouch. Really rather looking forward to getting it out there...
So, it's a 1997 car, it is a Cat C needing VIC, and it has some damage. However, these sell for £6-8k when in good condition, I paid less than a third of that. Time to play...
First view
Not too bad!
Yup, correct engine
Minty interior. 87k on the clock. Very nice! It's a 7 seater too...
Perfect seats with no bolster wear
And the damage
Front corner a bit bent, but nothing structural
Front missing
And the worst bit
A-pillar not bent though, and the door still aligns perfectly.
Story goes that the guy lost it and hit a lamppost. The guy I bought it from took it and started fixing it up, new suspension and wheel, although I suspect he did this mostly so he could move it around the workshop. He then ran out of time and/or interest to get it finished. So, it is now mine!
He presented me with the keys. This photo speaks the truth
Firstly, lets get it home...
My trusty e430 wagon doing sterling service as always, 600 mile round trip. Towed at 50mph as if nothing was behind it
Yes yes, possibly a trifle over weight, but it pulled like it wasn't there. Such great towing cars!9.7 litres and 16 cylinders in this pic
On the way home, I stopped in at another e55 (saloon) that was being broken for spares. Getting involved with a 12" petrol cutter the owner cut out the bits that are bent on mine. Took loads of spares inc. mint front wing and also got a spare set of front discs and callipers because... well, they are bloody expensive! Front discs are bespoke to the e55 and cost 600 quid a pair! These ones are better than what's on the car, so I will just reface them on the lathe at some point. All in £170 Result!
And home safe
Front bit of the repair panel is rather rusty, but that can be fixed later. Note, regulation custard creams on air box for grinder mission sustenance.
Damn, it took quite a knock here!
Lets have a look at this damage in more detail
It looks like someone has already been at this with a hammer. Hmmm.
Out with the grinder...
Cut as much bent bits out as possible.
And shape the spare part to fit. Measure twice, cut once!
Mock up with an old rusty wing.
Yup, panel gaps look about correct.
But first, need to cut out the rust in the repair panel.
Fixed!
Quick interlude to get rid of an old MX5 shell. Also got rid of my lovely '77 323 (orange bit of this photo). Pity, but it was just too far gone
Forgot to get a photo of it's last journey...For most of the repair, I will overlap the metal slightly to get a good weld, but the front bumper bar really needs a bit more strength than that and would look odd if overlapped. Therefore I will butt weld it, but with some strengthening behind.
So weld in this plate with some spots
Then weld the panel in.
The gap between the two panels there is deliberate enabling a good strong weld between the three bits of metal.
And finally, stitch it all in.
I now used the old wing to ensure everything still lines up correctly as I am welding. By cutting this hole, I can weld this seam without fear of it warping or moving out of shape.
Close up. Approx 5mm overlap to get a nice clean weld.
Once all done, they will all be coated in seam sealer, then lots of rustproofing!
So this is after about 3 evenings work. Unfortunately I ran out of welding gas, so had to to stop for the evening. Will update as I do more, but later, I get to play with this!
Borrowed from a mate, this will allow me to pull out the damaged outrigger as much as possible before then cutting out the damaged section and replacing it.
More soon
Comments, criticism, advice etc always welcome. I am just a hobbyist, and although quite confident at repairing rusty dross, never had a go at crash repair before, and just sort of making it up as I go. Therefore, I would be interested in any advice, especially if I could do anything better! Cheers!
myles1972 said:
Very interesting, once fixed you'll have a bahnstormer there!
Hope so 
Codswallop said:
Good skills OP. I remember reading about your DIY LPG install aswell on the E430 - will the E55 also be getting gassed?
Oh hell yeah! Sacrilege to some to LPG an AMG, but it's a keeper and it will do a lot of miles.It'll get a tow bar as well
Edited by Utterpiffle on Tuesday 27th August 16:35
Utterpiffle said:
Codswallop said:
Good skills OP. I remember reading about your DIY LPG install aswell on the E430 - will the E55 also be getting gassed?
Oh hell yeah! Sacrilege to some to LPG an AMG, but it's a keeper and it will do a lot of miles.It'll get a tow bar as well
These might come in handy for night time driving, especially as in my experience the standard W210 headlights are woeful:
http://item.mobileweb.ebay.co.uk/viewitem?sbk=1&am...
http://item.mobileweb.ebay.co.uk/viewitem?sbk=1&am...
Wow, great comments, I was expecting a flaming for the towing capers at the very least - seems to have been met with approval 
[quote=(steven)]Very good. I must sign up for those welding courses.
[/quote]
Well, when I started, I bought a welder off a mate, and got him to show me the basics of setting it up, then just practised. So long as you understand what is happening to the metal, it is very easy to pick up with a MIG. On saying that, I taught myself 20 years ago, so it is just sort of second nature these days.
[quote=martin mrt]Bookmarked, watching this with interest
[/quote]
Sadly no more updates for a while. Mrs Utterpiffle came back from her hols last night and has me penned in for decorating and floor laying duties for the next fortnight. Boo!
Oh, not true - I did seal/paint the front bit
Not particularly exciting!
[quote=Hooli]All estates should have a tow bar
[/quote]
This is very true! However, the e430 has a towing capacity of 2100kg. The e55 has a towing capacity of 0kg. Apparently it was never type approved for towing! Like that will stop me!
[quote=Leins]Something very cool about this pic. Best of luck with it BTW, proper "Super Saloon" that, despite being an estate!
[/quote]
Have another angle
[quote=Chunkychucky]...As for the 323, an E21? If so, any more pics? What was the story with it?
[/quote]
Sadly not - would have possibly put in more effort had it been an e21! Mazda 323 FA4. Last of the rear wheel drive ones. Unfortunately my barn leaked for 4 years whilst I was in Germany, and it rotted to a quite incredible level during that time! Pity really, it was a fun little thing, and I had planned to put MX-5 running gear in it.
After getting rid of all the old cars in the barn, I looked out of my front room window and realised that I now only own three vehicles (lowest number for years!), and they all have large v8 engines. Woo!
Next update in a few weeks hopefully...
[quote=(steven)]Very good. I must sign up for those welding courses.
[/quote]
Well, when I started, I bought a welder off a mate, and got him to show me the basics of setting it up, then just practised. So long as you understand what is happening to the metal, it is very easy to pick up with a MIG. On saying that, I taught myself 20 years ago, so it is just sort of second nature these days.
[quote=martin mrt]Bookmarked, watching this with interest
[/quote]
Sadly no more updates for a while. Mrs Utterpiffle came back from her hols last night and has me penned in for decorating and floor laying duties for the next fortnight. Boo!
Oh, not true - I did seal/paint the front bit
Not particularly exciting!
[quote=Hooli]All estates should have a tow bar
[/quote]
This is very true! However, the e430 has a towing capacity of 2100kg. The e55 has a towing capacity of 0kg. Apparently it was never type approved for towing! Like that will stop me!
[quote=Leins]Something very cool about this pic. Best of luck with it BTW, proper "Super Saloon" that, despite being an estate!
[/quote]
Have another angle [quote=Chunkychucky]...As for the 323, an E21? If so, any more pics? What was the story with it?
[/quote]
Sadly not - would have possibly put in more effort had it been an e21! Mazda 323 FA4. Last of the rear wheel drive ones. Unfortunately my barn leaked for 4 years whilst I was in Germany, and it rotted to a quite incredible level during that time! Pity really, it was a fun little thing, and I had planned to put MX-5 running gear in it.
After getting rid of all the old cars in the barn, I looked out of my front room window and realised that I now only own three vehicles (lowest number for years!), and they all have large v8 engines. Woo!
Next update in a few weeks hopefully...
Edited by Utterpiffle on Wednesday 28th August 10:07
Been a little while since an update. Not had time to play with cars recently. However, I did fire up the Car-B-Q for the first time
Oh, and this came up cheeeeep, so my lovely wife now has something rather fun to pootle about in. I am under strict instructions not to touch the suspension. Sigh, she knows me too well!
So I finally got a couple of days to play with the car. Woo!
Forgot to take pictures when playing with the strong arm ram, as it was quite fun pulling it all out. I couldn't get it quite as straight as I wanted, however, it did give me enough to then cut out the really bent bit and weld in the section from the other car.
After many many measurements and eyeing up the lines etc. I got to here
Slight improvement on before!
The inside doesn't look too pretty, but that was because I left sections out to then weld the layers inside the box section/sill section. This is just the patchwork that went in over the top. Wish I'd got some pictures inside as it turned out quite well. Still, I know if nothing else, it is certainly strong!
Sill section welded, then smoothed down
Rain didn't stop play. Just add a beer brolley
At least it will never rust!
Inside not too bad with some paint
And with the wing back on, it all looks reasonably straight. Not prefect, but it will do.
Also spent some time rebuilding the front suspension, as it still wasn't quite straight, and nothing was done up tight. New top link, new ARB link, new steering gator - standard stuff, but was nice just to play with normal oily stuff for a couple of hours....
Although we are busy this weekend, I have most of next week to play again, and hope to have it running very soon. Possibly a little ahead of myself, but I have booked the MOT and VIC for end of next week.
To do:
Fit interior
Pinch bumper off the e430
Run through and diagnose all the errors (currently BAS, ABS, Fluid levels and something else). I bought a star multiplexer diagnostic thingy for much money recently, so it will fun to play with that.
Rebuild suspension on other side (for piece of mind and also the excuse to get under there with the waxoil.
MOT
VIC test
Tax and insure
Tow bar
LPG
Then the fun begins...
More updates next week.
Oh, and this came up cheeeeep, so my lovely wife now has something rather fun to pootle about in. I am under strict instructions not to touch the suspension. Sigh, she knows me too well!
So I finally got a couple of days to play with the car. Woo!
Forgot to take pictures when playing with the strong arm ram, as it was quite fun pulling it all out. I couldn't get it quite as straight as I wanted, however, it did give me enough to then cut out the really bent bit and weld in the section from the other car.
After many many measurements and eyeing up the lines etc. I got to here
Slight improvement on before!
The inside doesn't look too pretty, but that was because I left sections out to then weld the layers inside the box section/sill section. This is just the patchwork that went in over the top. Wish I'd got some pictures inside as it turned out quite well. Still, I know if nothing else, it is certainly strong!
Sill section welded, then smoothed down
Rain didn't stop play. Just add a beer brolley
At least it will never rust!
Inside not too bad with some paint
And with the wing back on, it all looks reasonably straight. Not prefect, but it will do.
Also spent some time rebuilding the front suspension, as it still wasn't quite straight, and nothing was done up tight. New top link, new ARB link, new steering gator - standard stuff, but was nice just to play with normal oily stuff for a couple of hours....
Although we are busy this weekend, I have most of next week to play again, and hope to have it running very soon. Possibly a little ahead of myself, but I have booked the MOT and VIC for end of next week.
To do:
Fit interior
Pinch bumper off the e430
Run through and diagnose all the errors (currently BAS, ABS, Fluid levels and something else). I bought a star multiplexer diagnostic thingy for much money recently, so it will fun to play with that.
Rebuild suspension on other side (for piece of mind and also the excuse to get under there with the waxoil.
MOT
VIC test
Tax and insure
Tow bar
LPG
Then the fun begins...
More updates next week.
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff