Go Back  MBWorld.org Forums > Mercedes-Benz SUVs, Trucks, Vans, Diesels, Other > G-Class (W460, W461, W463)
2002 G500 build/ restoration/ conversion photo thread >

2002 G500 build/ restoration/ conversion photo thread

Notices
G-Class (W460, W461, W463) 1980-Present: 290 GD, 290 GDT, 300 GD, 350 GD, 500 GE, G 250, G 300, G 300 DT, G 320, G 500, G55 AMG

2002 G500 build/ restoration/ conversion photo thread

 
Old 03-23-2016, 09:23 PM
  #1  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
2002 G500 build/ restoration/ conversion photo thread

Hello everyone.
Couple months ago I picked up this 2002 Mercedes G500 for a very good price. Car needs some TLC, it's exactly what I was looking for. Over the next few months I am going to be repairing it, restoring it and updating it with 2016 G63 parts that I purchased from a forum member on here 👍😊.

I already took it apart and I apologize that I didn't take pictures off it right when I got it.

As you can see I already took off the front end, front axle, front suspension, exhaust, remove fender flares and rear bumper. My goal is to take it apart as much as I can, do some body repair and detail the undercarriage. I'm going to sand and soda blast the rust spots underneath and paint them with rust resistant paint.

I will try to post as much as I can on here.














































Last edited by Kobzarhomes; 03-23-2016 at 09:29 PM.
Kobzarhomes is offline  
Old 03-23-2016, 09:29 PM
  #2  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Few rust spots so far and few more out there. Overall there is not a lot of rust just in your typical places.




Driver side door mirror.





Could had previous damage / rust





Scratches on the hood





Couple of large stone chips and some rust
Kobzarhomes is offline  
The Following User Says Thank You to Kobzarhomes For This Useful Post:
Wassaby (04-08-2018)
Old 04-08-2016, 04:03 PM
  #3  
Junior Member
 
kotton's Avatar
 
Join Date: Apr 2013
Posts: 73
Thanks: 0
Thanked 1 Time in 1 Post
2011 E550 , 2006 G500
Awesome pics! Im looking forward to seeing the progress.
kotton is offline  
Old 04-08-2016, 04:08 PM
  #4  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Thanks! Was gone for couple weeks, eager to get back to work on it.
Kobzarhomes is offline  
Old 05-02-2016, 01:28 AM
  #5  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Been sand blasting the frame and suspension parts. Painted the front section of the frame with Eastwood Rust Encapsulator then go over with Undercoating. Going to start putting the front axle back on later this week and start taking the rear axle apart to paint the rear section and suspension components.







Last edited by Kobzarhomes; 05-02-2016 at 01:46 AM.
Kobzarhomes is offline  
Old 05-02-2016, 01:31 AM
  #6  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Doing some repair to the rear lid due to having spare tire dent.



Kobzarhomes is offline  
Old 05-02-2016, 01:43 AM
  #7  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Some of the products I use for frame restoration and treatment







Kobzarhomes is offline  
Old 05-03-2016, 07:36 PM
  #8  
Junior Member
 
kotton's Avatar
 
Join Date: Apr 2013
Posts: 73
Thanks: 0
Thanked 1 Time in 1 Post
2011 E550 , 2006 G500
How well do those rubberized undercoatings blend with the grey stuff that was put on from the factory?
kotton is offline  
Old 05-03-2016, 09:06 PM
  #9  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
My plan is just to put it on the frame and axles. My underneath is gray so I'm just going to steam clean it. I did not find any rust on the under body itself, just couple spots where some brackets were attached to it. Those will be spot treated and touched up.
Kobzarhomes is offline  
Old 05-05-2016, 01:20 AM
  #10  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Painted front suspension bits and front section of the frame with chassis paint. *new bushings on all the parts*













Kobzarhomes is offline  
Old 05-05-2016, 09:22 PM
  #11  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Front suspension coming together. G63 springs and shocks. Brand new bushings everywhere.

























Kobzarhomes is offline  
Old 05-07-2016, 10:53 PM
  #12  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Front suspension all assembled (besides brakes). Changing brake color from silver to red. Moving on to the rear end now👍











Kobzarhomes is offline  
Old 05-09-2016, 01:01 AM
  #13  
Senior Member
 
Join Date: Feb 2012
Location: ToRonTo, OnTaRiO, Khanaadah
Posts: 490
Thanked 18 Times in 17 Posts
s550
wow...impressive. can't wait to see the finished project. any plans for the interior?
just1time is offline  
Old 05-09-2016, 01:05 AM
  #14  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Thank you.
The plan is to completely reupholster the interior to a different color. Something similar to Barabus look.
Kobzarhomes is offline  
Old 05-10-2016, 07:41 PM
  #15  
Newbie
 
pitpro's Avatar
 
Join Date: Nov 2009
Posts: 7
Thanked 0 Times in 0 Posts
G500
Your skills are very impressive!
You will feel great driving that truck after
literally rebuilding her.
Those calipers look small for such a heavy
truck. No wonder I was always worried about
stopping in a hurry in my 2002.
pitpro is offline  
Old 05-10-2016, 07:57 PM
  #16  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Thank you
Hopefully the ones I got from G63 will do the trick 👍
Kobzarhomes is offline  
Old 05-11-2016, 08:58 PM
  #17  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Today I took apart the rear end suspension, dropped off rear links to get new bushings pressed in and replace passenger side axle with the one I got from G63. Axle replacement went very smoothly to my surprise : )














Last edited by Kobzarhomes; 05-11-2016 at 09:01 PM.
Kobzarhomes is offline  
Old 05-12-2016, 01:57 PM
  #18  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
G63 Front and rear calipers that I got came in silver, decided to paint them red.















Kobzarhomes is offline  
Old 05-12-2016, 09:19 PM
  #19  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Replace left rear axle and painted rear end frame and part of the rear axle.

































Kobzarhomes is offline  
The Following 2 Users Say Thank You to Kobzarhomes For This Useful Post:
8899 (01-04-2017), pitpro (05-12-2016)
Old 05-13-2016, 07:30 PM
  #20  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Painted rear links and finished painting rear axle.











Also sprayed "inner frame protective spray" in some of the frame crevices.





Last edited by Kobzarhomes; 05-13-2016 at 07:33 PM.
Kobzarhomes is offline  
Old 05-17-2016, 08:35 PM
  #21  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Assembled rear suspension. Next on the list is to install a new rotors and calipers.

























Kobzarhomes is offline  
The Following User Says Thank You to Kobzarhomes For This Useful Post:
pitpro (05-17-2016)
Old 05-18-2016, 05:38 PM
  #22  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Some more goodies arrived from parts.com. Miscellaneous gaskets, seals, molding, trim, grills, etc... Its about the details.



Kobzarhomes is offline  
The Following User Says Thank You to Kobzarhomes For This Useful Post:
pitpro (05-18-2016)
Old 05-23-2016, 01:44 AM
  #23  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Took off my original illuminated door sills today. Wanted to see how they are attached and if there will be any issues with attaching custom door sill I purchased. It appears they were original Mercedes sills and are attached with a double-sided tape to a plastic door sill which is attached to the vehicle. Looks like the once I purchased will work just fine 😊👍

















Kobzarhomes is offline  
Old 05-23-2016, 01:48 AM
  #24  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Here are the custom door sills I purchased.









Kobzarhomes is offline  
Old 05-23-2016, 01:52 AM
  #25  
Super Member
Thread Starter
 
Join Date: Dec 2012
Location: Seattle
Posts: 887
Thanked 114 Times in 87 Posts
2011 Mercedes E550 Sport
Removed all 4 window seals (on the outside of the door window). All were rusty. New replacements arrived couple days ago 👍


I'm pointing to which door window seals that I removed.


Kobzarhomes is offline  

Thread Tools
Search this Thread
Rate This Thread
Rate This Thread:
You have already rated this thread Rating: Thread Rating: 13 votes, 5.00 average.

Quick Reply: 2002 G500 build/ restoration/ conversion photo thread


Contact Us - About Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.
 
  • Ask a Question
    Get answers from community experts
Question Title:
Description:
Your question will be posted in:
You Rated this Thread: 5