Re: The Lost World - Mercedes ML (W163) Montana project
Posted: May 28th, 2022, 2:33 pm
That's a great compliment! Thanks so much! I think however I need to let you down... It's so much work and there is so little information to go on about the ML's. I'm probably never doing this car again That's why I want to have it on this forum. I hope we can inspire others to take the job!
Update May 2022:
After last update we've welded everything together and smoothed it out as much and clean as possible. We're very happy with the results.
This (long) weekend the rear bumper was next on the list to tackle. Luckily we kept the cart board bumper template. It was very easy to create all parts needed to create the bumper. After cutting the holes, grinding them down and dimple die-ing/flairing the holes it could be tack welded into shape.
From template to steel bumper (and it's great temporary setup ).
Bracket:
Off course the steel bumper needs to be mounted in a good way. After we removed the bumper we happen to see some weird bolts. They go through and through the rear crash bar. I'm not exactly sure where they are for, but they could be removed and changed into exactly what we needed.
The weird bracket that comes out when unbolted. We decided to extend these to make a bracket for the steel bumper.
The temporary setup once the bumper cover was removed. Making sure it was exactly high enough.
The OEM Mercedes brackets are no longer OEM. Welded solid.
Cut the holes in the bumper. Once the bumper is black and the steel bumper goes over it you won't them anymore.
Perfectly positioned between two of the flaired holes in the steel bumper. The bracket also has some margin to move the stee bumper in exactly the right spot.
All other holes (electrical, tow hitch and exhaust) are cut, so we're still able to install the removable tow hitch.
Once the bumper and brackets were finished it was time to install all the created parts to see how it looks all together.
Starting to look like it, right?