The Lost World - Mercedes ML (W163) Montana project
Posted: January 3rd, 2022, 7:08 am
Hi all! As promised in the "Introductions" part of the forum I would open a Build topic for my Mercedes ML 'Montana' project.
A few years ago, when the video-tape was still a hot item, I watched the Jurassic Park movies. Ever since I saw those movies I wanted one of those SUV's (and the Lost World RV off course!).
Mercedes ML:
As a Jeep Wrangler and Ford Explorer are quite rare here in Europe (and especially the car-hating country of the Netherlands, who charge 125.000 euro's for a simple hybrid Chrysler Pacifica), the ML seems to be the one to do. I like the looks of the ML's in the movie and I see there are not a lot of them out there.
Picked her up just 30 minutes from home.
Completely coincidental (not because I wanted to have my own JP car, but because I needed a towing vehicle to finish our garden off course ) I stumbled upon this 2000 Mercedes ML320 with around 155.000 miles (250.000 km) on the clock. Not maintained for a long time and leaking all kinds of oil from everywhere. Sometimes that is a 'good' thing, because I got her cheap.
Kaboom
After the needed TLC (all fluids and filters), a 'new' transfer case and a bunch of new seals I drove her around for about 5000 km's and really finished the garden. This is the perfect basis for the build.
The plan:
If I'm correct, there are 3 versions of the ML:
- Santana, the pick-up truck,
- Fontana, the one with the boxes on the side rear windows and
- Montana, the one with the window bars all around the sides and back.
In the first part of the movie you see all three versions next to the RV in the warehouse. When they are transported to Isla Sorna you see only two of the ML's came along. The story goes that because of the lack of a extra driver the third ML doesn't go.
Montana
Anyhow! That third ML seems to be the most practical of the three. I don't like a few details of the car (the black bumpers on the doors and the strange looking box on the hood for example). A few details on the other ML's I like which Montana doesn't have. So, we (yes, "we", because my brother-in-law is helping out) will use Montana as an inspiration instead of creating a exact replica.
Sourcing parts and materials:
Tires:
First thing we did is search for tires. I searched for the original Dunlop Mud Rovers in 16 inch. Those tires are discontinued, so that wasn't an option anymore. Funny fact is that while searching for Mud tires I found out that these alloy wheels are available in 16 and 17 inch. My ML came with the 17 inch wheels, which made it way easier to find a descent looking tire. Eventually we settled on the Toyo Open Country Mud Terrains because of the looks.
Montana's new shoes
Window Bars:
Next up are the window bars (work in progress). We needed something around 20-25mm according to our professional, scientific calculations (done on a few pictures). We settled on 22mm, because that is what a friend had laying around in his garage (heating pipes).
Setting up where those bars need to be, again the pictures and our calculations helped
Removing the C-pilar caps, cutting the strips which hold the bars, drilling holes in the car, installing rivet nuts
Bending the entire pipe to wrap around the car
Cutting, grinding, welding
Looks from the rear
We still have to do the driver- and all passenger side windows, but the rears are definitely the hardest.
Steel bumpers and winch:
We ran out of welding gas in the middle of the weekend, so instead we already created a template for the bumpers. Again, using a lot of photo measurements and information I got from a fellow ML-builder. We started with the front bumper as those are the hardest.
We created the templates out of cart board, so they can be easily cut out of steel. The big box is a reference for the winch
For reference
The winch is officially a Warn M5000 if I'm correct. They are very, very hard to find. Let alone find one in Europe. It can't be done. So instead we've opted for a look-a-like from a generic brand. I don't think we will use it that much (if ever), but I want to be able to use it if we want. On the movie car the winch is mounted on steel base plates which are welded/bolted to the crash structure of the chassis. I found out that we need special bolts if we bolt it on (which is the smartest thing to do, because I don't know if we are allowed to have it exposed here in the Netherlands).
The winch.
That's it so far. We're still making a lot of progress during the weekends. I will keep you guys (and girls) updated if you like.
A few years ago, when the video-tape was still a hot item, I watched the Jurassic Park movies. Ever since I saw those movies I wanted one of those SUV's (and the Lost World RV off course!).
Mercedes ML:
As a Jeep Wrangler and Ford Explorer are quite rare here in Europe (and especially the car-hating country of the Netherlands, who charge 125.000 euro's for a simple hybrid Chrysler Pacifica), the ML seems to be the one to do. I like the looks of the ML's in the movie and I see there are not a lot of them out there.
Picked her up just 30 minutes from home.
Completely coincidental (not because I wanted to have my own JP car, but because I needed a towing vehicle to finish our garden off course ) I stumbled upon this 2000 Mercedes ML320 with around 155.000 miles (250.000 km) on the clock. Not maintained for a long time and leaking all kinds of oil from everywhere. Sometimes that is a 'good' thing, because I got her cheap.
Kaboom
After the needed TLC (all fluids and filters), a 'new' transfer case and a bunch of new seals I drove her around for about 5000 km's and really finished the garden. This is the perfect basis for the build.
The plan:
If I'm correct, there are 3 versions of the ML:
- Santana, the pick-up truck,
- Fontana, the one with the boxes on the side rear windows and
- Montana, the one with the window bars all around the sides and back.
In the first part of the movie you see all three versions next to the RV in the warehouse. When they are transported to Isla Sorna you see only two of the ML's came along. The story goes that because of the lack of a extra driver the third ML doesn't go.
Montana
Anyhow! That third ML seems to be the most practical of the three. I don't like a few details of the car (the black bumpers on the doors and the strange looking box on the hood for example). A few details on the other ML's I like which Montana doesn't have. So, we (yes, "we", because my brother-in-law is helping out) will use Montana as an inspiration instead of creating a exact replica.
Sourcing parts and materials:
Tires:
First thing we did is search for tires. I searched for the original Dunlop Mud Rovers in 16 inch. Those tires are discontinued, so that wasn't an option anymore. Funny fact is that while searching for Mud tires I found out that these alloy wheels are available in 16 and 17 inch. My ML came with the 17 inch wheels, which made it way easier to find a descent looking tire. Eventually we settled on the Toyo Open Country Mud Terrains because of the looks.
Montana's new shoes
Window Bars:
Next up are the window bars (work in progress). We needed something around 20-25mm according to our professional, scientific calculations (done on a few pictures). We settled on 22mm, because that is what a friend had laying around in his garage (heating pipes).
Setting up where those bars need to be, again the pictures and our calculations helped
Removing the C-pilar caps, cutting the strips which hold the bars, drilling holes in the car, installing rivet nuts
Bending the entire pipe to wrap around the car
Cutting, grinding, welding
Looks from the rear
We still have to do the driver- and all passenger side windows, but the rears are definitely the hardest.
Steel bumpers and winch:
We ran out of welding gas in the middle of the weekend, so instead we already created a template for the bumpers. Again, using a lot of photo measurements and information I got from a fellow ML-builder. We started with the front bumper as those are the hardest.
We created the templates out of cart board, so they can be easily cut out of steel. The big box is a reference for the winch
For reference
The winch is officially a Warn M5000 if I'm correct. They are very, very hard to find. Let alone find one in Europe. It can't be done. So instead we've opted for a look-a-like from a generic brand. I don't think we will use it that much (if ever), but I want to be able to use it if we want. On the movie car the winch is mounted on steel base plates which are welded/bolted to the crash structure of the chassis. I found out that we need special bolts if we bolt it on (which is the smartest thing to do, because I don't know if we are allowed to have it exposed here in the Netherlands).
The winch.
That's it so far. We're still making a lot of progress during the weekends. I will keep you guys (and girls) updated if you like.