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
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.
So it is beginning to look like a working car again!
I have had to borrow the front bumper from my old E430. It is not the correct one, but will have to do for now, as even second hand e55 bumpers seem to sell for about a third of what I paid for the whole car. Something will no doubt turn up one day. But in the mean time, this will have to do. I must confess I am half tempted to go for the sleeper look and lose the AMG body kit completely/remove the badges - make it look like a standard e200 or similar. Anyway, need to get it road legal first!
I thought all the welding was complete, but found this little hole behind the rear wheel by the fuel filler this morning, so welded that up.
I've had a good look around it and fixed all the problems I can see ready for MOT. Connected up an old laptop to clear the SRS fault.
Update:
So, bad news - failed MOT. Good news, only failed on a small patch of welding behind the wheel on the other side and headlight alignment was out - a long way out on the crashed side, and we couldn't adjust it in.
However, bloody hell it drives well! Not quite as quick off the mark as I was expecting, but put foot to the floor at 50 and it feels good! Alignment is definitely out though as it was pulling slightly - will get that sorted next week.
I have done the welding this afternoon, and "hard-adjusted" the headlight. I could see how far out is was on the testing machine, so drew up in front of my barn door then drew a line in chalk on the door where the pattern cutoff was. I then adjusted it down as required. It might still be a little out, but nothing that we can't tune out at the garage.
At 8am tomorrow, I should have a fresh MOT, and then just the VIC check to get through at midday - although from what I can make out, this is just a formality.
Tow bar tomorrow afternoon I think...
I have had to borrow the front bumper from my old E430. It is not the correct one, but will have to do for now, as even second hand e55 bumpers seem to sell for about a third of what I paid for the whole car. Something will no doubt turn up one day. But in the mean time, this will have to do. I must confess I am half tempted to go for the sleeper look and lose the AMG body kit completely/remove the badges - make it look like a standard e200 or similar. Anyway, need to get it road legal first!
I thought all the welding was complete, but found this little hole behind the rear wheel by the fuel filler this morning, so welded that up.
I've had a good look around it and fixed all the problems I can see ready for MOT. Connected up an old laptop to clear the SRS fault.
Update:
So, bad news - failed MOT. Good news, only failed on a small patch of welding behind the wheel on the other side and headlight alignment was out - a long way out on the crashed side, and we couldn't adjust it in.
However, bloody hell it drives well! Not quite as quick off the mark as I was expecting, but put foot to the floor at 50 and it feels good! Alignment is definitely out though as it was pulling slightly - will get that sorted next week.
I have done the welding this afternoon, and "hard-adjusted" the headlight. I could see how far out is was on the testing machine, so drew up in front of my barn door then drew a line in chalk on the door where the pattern cutoff was. I then adjusted it down as required. It might still be a little out, but nothing that we can't tune out at the garage.
At 8am tomorrow, I should have a fresh MOT, and then just the VIC check to get through at midday - although from what I can make out, this is just a formality.
aspirated said:
Great progress, wet sand your headlights though
Yes sir! I put a mop on the drill this evening and give the headlights a good polish (using t-cut). Wow, what a difference! They were yellow, now they look shiny clear like new. Amazing difference for 15 mins with the drill. Didn't get a photo as it was getting dark, but I am sure you all know what the headlights look like! I will have to do my wifes CLK tomorrow.Tow bar tomorrow afternoon I think...
Lee540 said:
What the hell!!
Reshell with a lower spec car?
It is all a bit strange... I have asked for some advice with the full story on the general forum. Hope to get some useful info. hread link here:Reshell with a lower spec car?
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
Evo said:
Re Your hole in the boot, I did exactly the same with mine, except it was a lot worse than that, nearly had heart failure lol
Have you checked the other side under the spare wheel...........
When I bought the car it had no spare wheel, and I could see the floor through the wheel well. Bloody great big hole! Sorted that one a while back. Both sides now welded up. It will certainly not rust any further! Have you checked the other side under the spare wheel...........
The body shells are exactly the same, including the sunroof (which is jammed on the 430). However, the 430 is knackered - very rusty, not just body, but brake pipes etc too. Worn suspension etc. Lovely old car as it is, it has had it's day. You'd be amazed just how many parts are different on the AMG cars.
Yes I could just swap the plates or even swap the VIN plates (windscreens out and my welding is good enough to swap the tags), but I'd then never be able to sell the 55, even abroad as it would still be a 430 on the papers. Also my wife drives with family in the car and VOSA do have a habit of stopping cars on our road. Just not worth the risk. The car has to be legit and legal.
I am just gong to send all the papers off to the DVLA as advised and see what happens...
It's a bit odd really, but now I have calmed down, it just adds to the challenge I will get it back on the road somehow, and continued regardless yesterday by fixing the heater, the heated seats, some trim and the stereo. Well, actually, I broke the stereo, but that's by the by.
Will update in a week or so I guess when I hear back from the DVLA, but for now I will continue fitting the tow bar and LPG as per plan A.
Yes I could just swap the plates or even swap the VIN plates (windscreens out and my welding is good enough to swap the tags), but I'd then never be able to sell the 55, even abroad as it would still be a 430 on the papers. Also my wife drives with family in the car and VOSA do have a habit of stopping cars on our road. Just not worth the risk. The car has to be legit and legal.
I am just gong to send all the papers off to the DVLA as advised and see what happens...
It's a bit odd really, but now I have calmed down, it just adds to the challenge
I will get it back on the road somehow, and continued regardless yesterday by fixing the heater, the heated seats, some trim and the stereo. Well, actually, I broke the stereo, but that's by the by.Will update in a week or so I guess when I hear back from the DVLA, but for now I will continue fitting the tow bar and LPG as per plan A.
Looking on the tax website, I could see that the VIC marker had been removed.
I filled in the v5 application form and the tax disc form and sent them off to the DVLA. As of yesterday lunchtime, the car is now showing online as taxed (although the disc hasn't come through the door yet).
I phoned the DVLA yesterday, I should get the tax disc tomorrow, and the v5 application will apparently be processed on the 4th November.
As soon as the disc turns up, I consider the car legal - i.e. I have insurance, MOT and tax. Actually, apart from failure to display, I suppose I could drive it now, but I can wait another day. Hmm, well, it does need some petrol...
The v5 can then follow whenever it likes.
With regards to the insurance - the company have no problem with it being a cat b, the only stipulation being that if the car is damaged or stolen, the value will be regarded as scrap. A risk I will have to take.
Not had much time to work on the car recently unfortunately, as job hunting is surprisingly time consuming! However, I have fitted the tow bar and removed the e55/AMG badges, so not all lost. Now that the towbar is in, I can start the LPG conversion. Pictures to follow on that.
I filled in the v5 application form and the tax disc form and sent them off to the DVLA. As of yesterday lunchtime, the car is now showing online as taxed (although the disc hasn't come through the door yet).
I phoned the DVLA yesterday, I should get the tax disc tomorrow, and the v5 application will apparently be processed on the 4th November.
As soon as the disc turns up, I consider the car legal - i.e. I have insurance, MOT and tax. Actually, apart from failure to display, I suppose I could drive it now, but I can wait another day. Hmm, well, it does need some petrol...
The v5 can then follow whenever it likes.
With regards to the insurance - the company have no problem with it being a cat b, the only stipulation being that if the car is damaged or stolen, the value will be regarded as scrap. A risk I will have to take.
Not had much time to work on the car recently unfortunately, as job hunting is surprisingly time consuming! However, I have fitted the tow bar and removed the e55/AMG badges, so not all lost. Now that the towbar is in, I can start the LPG conversion. Pictures to follow on that.
Edited by Utterpiffle on Tuesday 22 October 11:14
The Nur said:
Excellent news! You must be pretty pleased
I thought you could drive a vehicle without having to worry about not displaying if the tax disk was bought online?
Cheers, I am! I thought you could drive a vehicle without having to worry about not displaying if the tax disk was bought online?
You are allowed to not display if the old has just run out and you've applied for a new one. Rule doesn't apply if the car was sorn or written off.
Ahha, here we are...
The e55 has been on the road for a couple of months now. Done around 2500 miles in that time. Apart from some issues with the rear suspension alignment (still to be fixed, although I did order the part yesterday), and the backrest of the drivers heated seat packing up, it has been a really nice car.
It is now de-badged, and I have had some fun at the traffic lights
However, it is terrible on fuel! Yes, I was expecting this, but it really is far worse than the e430 ever was. 25-ish mpg on a run, but almost single figures around town. Gulp.
I have finally found some time to LPG it this week, so will try to run a daily diary...
The e55 has quite a bit of space down to the left as you look in the engine bay - it is where the air box goes on lesser cars. This is where I will put the reducers++ and solenoid / filters etc.
++ 2 reducers. I went for the Magic Jet 3 reducer as it is physically tiny compared to other reducers and has a reasonably good review. It comes in 250 or 350 bhp varieties. Although my car is rated at 350bhp, I had read that the Magic runs out of puff at it's limits. There were only 45 quid each, so I opted to 2 of the 250Bhp ones. Made the plumbing a little more complicated, but hey, it's all good fun!
So, yesterday evening, I made a bracket and welded it in
Test fit behind the offside headlight
And painted
Left it to dry overnight.
Today, plumbing. Not sure if you can see the inlet water pipes and Y'd together underneath. This will then be T'd to the water system just there by the auxillary heater pump (which is the heater inlet).
The high pressure gas inlets are T'd and piped to the Solenoid. Normally, the reducers themselves have a safety solenoid built in, so I will put a second one along the line.
A few hours later, and I had plumbed in the low pressure gas side, silver cans are just filters. I wanted to make sure these are on top, as they are a serviceable items. The two outputs from these will go the two injector rails.
The two pipes around the outside of the filters are the water outlets, which are Y'd together, then go around the back of the engine to the heater outlet. As such the water effectively runs in parallel to the heater system, so it will always get warm water, whether the heater is on or not. What looks like extra outputs on the water outputs are just temporary, as I needed to order some right angle elbows, but the T's were all I had, so used just so I could cut all the pipes and mock it up.
I ran out of parts to finish off the the reducer bit, so cracked on with the injectors. It was dark by the time I took this photo, but it shows the 8 injector pipes coming up ready for the LPG injectors.
I have mentioned these wonderful things in a previous LPG build, but they really are a massive time saver. You pull off the injector rail and injectors, insert the little adaptors with the extra feed, then put the injector rail back on, bolted to little standoffs. The result is firstly that you don't have to drill and tap the inlet manifold (risky and time consuming!), but also, it ensures that the LPG fuel goes in where Mercedes intended - i.e. down the injector hole!
I ran out of light and feeling in my hands. The fog had dropped and started freezing! Hopefully the elbows and extra pipe will arrive tomorrow so I can finish the water system. Hopefully another update tomorrow evening. Cheers!
The e55 has been on the road for a couple of months now. Done around 2500 miles in that time. Apart from some issues with the rear suspension alignment (still to be fixed, although I did order the part yesterday), and the backrest of the drivers heated seat packing up, it has been a really nice car.
It is now de-badged, and I have had some fun at the traffic lights
However, it is terrible on fuel! Yes, I was expecting this, but it really is far worse than the e430 ever was. 25-ish mpg on a run, but almost single figures around town. Gulp.
I have finally found some time to LPG it this week, so will try to run a daily diary...
The e55 has quite a bit of space down to the left as you look in the engine bay - it is where the air box goes on lesser cars. This is where I will put the reducers++ and solenoid / filters etc.
++ 2 reducers. I went for the Magic Jet 3 reducer as it is physically tiny compared to other reducers and has a reasonably good review. It comes in 250 or 350 bhp varieties. Although my car is rated at 350bhp, I had read that the Magic runs out of puff at it's limits. There were only 45 quid each, so I opted to 2 of the 250Bhp ones. Made the plumbing a little more complicated, but hey, it's all good fun!
So, yesterday evening, I made a bracket and welded it in
Test fit behind the offside headlight
And painted
Left it to dry overnight.
Today, plumbing. Not sure if you can see the inlet water pipes and Y'd together underneath. This will then be T'd to the water system just there by the auxillary heater pump (which is the heater inlet).
The high pressure gas inlets are T'd and piped to the Solenoid. Normally, the reducers themselves have a safety solenoid built in, so I will put a second one along the line.
A few hours later, and I had plumbed in the low pressure gas side, silver cans are just filters. I wanted to make sure these are on top, as they are a serviceable items. The two outputs from these will go the two injector rails.
The two pipes around the outside of the filters are the water outlets, which are Y'd together, then go around the back of the engine to the heater outlet. As such the water effectively runs in parallel to the heater system, so it will always get warm water, whether the heater is on or not. What looks like extra outputs on the water outputs are just temporary, as I needed to order some right angle elbows, but the T's were all I had, so used just so I could cut all the pipes and mock it up.
I ran out of parts to finish off the the reducer bit, so cracked on with the injectors. It was dark by the time I took this photo, but it shows the 8 injector pipes coming up ready for the LPG injectors.
I have mentioned these wonderful things in a previous LPG build, but they really are a massive time saver. You pull off the injector rail and injectors, insert the little adaptors with the extra feed, then put the injector rail back on, bolted to little standoffs. The result is firstly that you don't have to drill and tap the inlet manifold (risky and time consuming!), but also, it ensures that the LPG fuel goes in where Mercedes intended - i.e. down the injector hole!
I ran out of light and feeling in my hands. The fog had dropped and started freezing! Hopefully the elbows and extra pipe will arrive tomorrow so I can finish the water system. Hopefully another update tomorrow evening. Cheers!
griffin dai said:
What are these mate?
If your after some extra bit of oomph and a better growl, fit an x-pipe
I also had a sprint booster fitted to mine, it came with the car but the previous owner said it made a nice difference and perked things up a bit.
I tried a couple different air filters but found the standard MANN filters worked best, the K&N panel filter shagged the MAF sensor so performance dropped right off! 0-60 was getting close to 8.5 secs! New filters...back to 5.3
Sorry, maybe I should have called them vapourisers, rather than reducers...If your after some extra bit of oomph and a better growl, fit an x-pipe
I also had a sprint booster fitted to mine, it came with the car but the previous owner said it made a nice difference and perked things up a bit.
I tried a couple different air filters but found the standard MANN filters worked best, the K&N panel filter shagged the MAF sensor so performance dropped right off! 0-60 was getting close to 8.5 secs! New filters...back to 5.3
X-pipe really make that much difference? A mate works for Powerflow exhausts, so it will paying a visit there at some point. Don't think I want it loud though - really rather enjoy the stealthy look!
Art0ir said:
Those adapters look like a great job! I wonder why they're not more widespread?
I think they are a relatively new concept, hope they will become more popular, I have had great results with them. I first used them about 2 years ago. I notice more LPG suppliers in the UK are stocking them now though, although I bought these from Poland for about a quid each!It has been pointed out to me on the LPG forum that I should be using 8mm pipe for a 350bhp engine, not 6mm. Pleased I read this now, as I was going to run the fuel pipe today. It does mean that I also need an 8mm solenoid, so it does potentially put me back a day or two as I need to order a couple of parts... Still plenty to get on with today though.
You gained 30 bhp just from the exhaust? Just in two minds about exhaust note at the moment, as when I have gone for louder exhausts on other Mercs, it also gives a horrible booming sound in the cabin at cruising speed. I also don't usually want to draw attention to my car! But then, V8.
griffin dai said:
Well worth registering here mate-
http://mbworld.org/forums/w210-amg-82/
There's a US firm called AMS who do some nice bits for it, like headers and the pulley kit. Then again of you can get the exhaust done for cheap with a friend.....big shiny headers would be on the list
I had a full magnaflow system on mine, sounded lovely! Really wanted to decat the system and get a more aggressive exhaust note plus aim for over 400bhp (was 381) but lost my job so had to sell it
Ahha, looks like an active AMG forum, thank you! http://mbworld.org/forums/w210-amg-82/
There's a US firm called AMS who do some nice bits for it, like headers and the pulley kit. Then again of you can get the exhaust done for cheap with a friend.....big shiny headers would be on the list
I had a full magnaflow system on mine, sounded lovely! Really wanted to decat the system and get a more aggressive exhaust note plus aim for over 400bhp (was 381) but lost my job so had to sell it
You gained 30 bhp just from the exhaust? Just in two minds about exhaust note at the moment, as when I have gone for louder exhausts on other Mercs, it also gives a horrible booming sound in the cabin at cruising speed. I also don't usually want to draw attention to my car! But then, V8.
So, 2 days worth to update with - or at least 2 half days, as stuff always gets in the way...
I am not being quite as methodical as usual, as I am still missing a few parts. As such, I am not really able to finish one bit before moving on to the next. However, good progress has been made.
So this was the state of play after day 1
Day 2
I have finished the water cooling system, started the car and brought it up to temperature. No leaks. Considering I have added 20 jubilee clips to the cooling system, this is good! Also, the reducers are getting nice and warm as required.
I needed to do some wiring next, as the injectors are hard wired to the loom.
This is the loom. Nicely labelled so easy (ish) to fit!
The ECU, as per my e430 build fits just snugly in the box with the other ECU's. Almost like it was meant to be there!
Photo here before loom attached.
By the end of day 2 - actually only got about 3 hours in the end - the loom was roughly laid in place and some of it attached. It is amazingly time consuming laying wires and attaching it so it looks neat. I want it to look as close to a factory install as possible.
Injectors connected up and loom laying roughly where it supposed to go.
Day 3 - again, about 3 hours
Rain didn't stop play!
So the wiring is now complete, except the solenoid and fuel gauge wires that go to the back. I think it looks reasonably neat.
Fuel gauge and selection switch nicely hidden in the ash tray
Gone!
Towards the end of the day, I started playing with the air filter housing. This is the only part I am not sure how to do at the moment. Unfortunately with any LPG install, there is going to be a certainly amount of compromise. On this one, I think I will have to reduce the air input slightly. The e55 has double the air filter surface area of the e430, so I hope it can cope if it looses a bit. If this doesn't work, I will have to come up with some sort of ricer induction kit thing, but would obviously prefer it to look stock in the engine bay...
So, the photo below is where I got too before it got too dark/cold. Or more to the point, it's Friday and my lovely wife wants us to go to the pub!
Rubbish photo, but you can see that I have had to cut out quite a bit to get the housing to fit over the injectors. I don't think it will actually make a massive impact on the air flow, as there is very little input volume in the middle there anyway. In real terms, I reckon less than 10% reduction. Will see in the next few days if it is going to work...
Next update hopefully Monday evening...
I am not being quite as methodical as usual, as I am still missing a few parts. As such, I am not really able to finish one bit before moving on to the next. However, good progress has been made.
So this was the state of play after day 1
Day 2
I have finished the water cooling system, started the car and brought it up to temperature. No leaks. Considering I have added 20 jubilee clips to the cooling system, this is good! Also, the reducers are getting nice and warm as required.
I needed to do some wiring next, as the injectors are hard wired to the loom.
This is the loom. Nicely labelled so easy (ish) to fit!
The ECU, as per my e430 build fits just snugly in the box with the other ECU's. Almost like it was meant to be there!
Photo here before loom attached.
By the end of day 2 - actually only got about 3 hours in the end - the loom was roughly laid in place and some of it attached. It is amazingly time consuming laying wires and attaching it so it looks neat. I want it to look as close to a factory install as possible.
Injectors connected up and loom laying roughly where it supposed to go.
Day 3 - again, about 3 hours
Rain didn't stop play!
So the wiring is now complete, except the solenoid and fuel gauge wires that go to the back. I think it looks reasonably neat.
Fuel gauge and selection switch nicely hidden in the ash tray
Gone!
Towards the end of the day, I started playing with the air filter housing. This is the only part I am not sure how to do at the moment. Unfortunately with any LPG install, there is going to be a certainly amount of compromise. On this one, I think I will have to reduce the air input slightly. The e55 has double the air filter surface area of the e430, so I hope it can cope if it looses a bit. If this doesn't work, I will have to come up with some sort of ricer induction kit thing, but would obviously prefer it to look stock in the engine bay...
So, the photo below is where I got too before it got too dark/cold. Or more to the point, it's Friday and my lovely wife wants us to go to the pub!
Rubbish photo, but you can see that I have had to cut out quite a bit to get the housing to fit over the injectors. I don't think it will actually make a massive impact on the air flow, as there is very little input volume in the middle there anyway. In real terms, I reckon less than 10% reduction. Will see in the next few days if it is going to work...
Next update hopefully Monday evening...
Edited by Utterpiffle on Saturday 14th December 10:44
piers1 said:
What a result after the cat B fiasco! How come they suddenly taxed it though, seems odd, as surely once it is a cat B, it is a cat B? Did they say?
Local DVLA office were wrong. Car has an MOT and a valid VIC cert. The insurance category is nothing to do with them, so Mrs Busybody-DVLA-clerk in the local office should have just done her job. I sent it all off, tax disc turned up a week later, then followed by a V5C three weeks after that. Fully road legal. A cat-B car "shouldn't" go back on the road. Luckily, that doesn't mean it can't.Only issue is that if I do have an accident in it, the insurance company will consider it scrap value only.
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