My Euro 500SEC Project
I normally hang out on some other Mercedes forums, I don't have time for all of them. I gather a lot of useful information from this forum, so I figured I would start posting here a little more and inform you guys of my current project.
Day 1:
The car is a 1984 500SEC. It is Midnight Blue over "255". Can anyone tell me what code 255 corresponds to? The car was originally sold in Braunschweig, Germany, and later was imported from Stuttgart to Florida. The car is in overall pretty good shape, but it is by no means perfect. It has covered 81K miles since new.
The car will be undergoing many phases of restoration/fixing up. I didn't have time to do anything to the car today except for give it a good wash inside and out. Tomorrow I will begin the fixing/detailing stages. In the near future the car will be completely disassembled, stripped, and professionally repainted and reassembled with all new seals/rubber/plastic. At one point in the cars life, it received a decent paint job, but with bad prep. As a result the paint is starting to flake off in a couple areas.
I got caught up with some other things this afternoon, and wasn't able to get any pictures until just now. So sorry for the dark, not so great pictures. I promise tomorrow you guys will have all the pictures you could wish for.


Hope to see you guys 'round!
Before:

After: (Don't mind the "digital tape" lol. I started to take the tape off on accident. Also, there is still dust from the polishing. This is just a quick n' dirty)

Day 2:
In other news, I got a lot done on the car today. I got rid of a bunch of federalization/emission work around parts. I got the driver side seat belt arm working again. I removed some old wiring and misc pieces from what I think might have been an aftermarket alarm at one point. I cleaned out the area under the battery tray and fuse box, I also repainted the battery tray. I got the whole car compounded, and partially polished, but it was too dark to finish polishing and wax it. Will have to continue that tomorrow. I will have a bunch of pictures later tonight.
I am going to make a few videos of the car since I didn't have time for a proper photoshoot.
While I wait for the video to upload, here are a few pictures from today.
Battery Box full of leaves and misc. I cleaned it out at the recommendation of some other members on the forum.
Before:

After:

Also stripped all the old paint off the battery tray and repainted it

I somehow failed to get an after picture...lol.
Removing all non-factory wiring mess:

Here is an interior shot that wasn't taken at midnight, lol.

The part of the car that gets the most comments:

My personal favorite:

Hard at work fixing every misc. thing I can find:

Day consisted mostly of compounding/polishing the car. I only got done with the polishing and wasn't able to put wax on it tonight.

Looks pretty good without wax though:

Video in a second...
Sorry the 0-60 somehow turned into a 0-55, lol. I guess I messed up somewhere...
YouTube - 1984 Euro 500SEC 0-60 MPH
YouTube - 1984 Euro 500SEC Revving
I replaced every single bulb in the interior, all with bulbs with a slightly higher wattage than stock. I am extremely pleased with the result. When everything it lit up nicely, it really looks good. I also "rebuilt" the two overhead lights which had become yellow & full of dirt over time. Both look like new again. I also polished the cluster plastic, as it was a bit hazy.

Tomorrow is a mini road trip to a recycled euro parts place near here. Hoping to score a new intake box from a later 560 (the dual-intake unit), as mine was hacked up to fit a air pump for emissions testing. I'm sure I'll find some more things as well.
I went to the junk yard looking for a bunch of misc. stuff. I got a new trunk light switch/holder thing as mine was missing/broken.
Picked up a new air box top, as mine was pitted. Its in the process of being polished to perfection. Found an air box from a late 560SL which had a large driver side air intake. Also picked up a new passenger side intake for my box.
As AMG did in the 80's, I began adding the driver side intake to my remaining air box to have a dual intake setup.
Here are the pictures (Thanks to my friend for letting me borrow his because I am an idiot and forgot mine!):
Two culprits:

Began cutting the inlet attachment part out of the SL's airbox:

...And then we got impatient:

Cut out:
v

Flattened:

Clamps are your friend:

Traced:

Cut and bent.

Riveted on along with passenger side unit:

And there you have it!:

I'll clean it up and post pictures installed later! Enjoy guys!

The entire engine bay still needs to be thoroughly cleaned and polished/detailed. That is one of this weeks projects.
Tomorrow I will clean and polish this intake and get it all installed back in the car. my K&N air filter should be here tomorrow as well.
Here is the engine bay before the cleaning. During and after pictures will follow tomorrow. Nice and clean, huh! :

Also, received the wheels I'll be using on this car for a while. They are AMG Aero 1's. (17" ET11). When I paint the car (if I still have these wheels then) I will be getting them all refinished black with a polished lip:

Here is a picture of whats to come in the next few weeks, can you spot all of the differences?:

Enjoy guys! Look for another update shortly!
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My main goal was to "Defederalize" the front and rear bumpers. Basically when a lot of these cars were imported, in order to keep the Euro bumpers a piece of metal was attached to the stock bumper beams. All of the ones I have seen, including mine, look like something I made in my backyard. They are poorly constructed, and I don't believe serve any other purpose other than adding 20lbs to each bumper.
Front end disassembled:

Here are a few pictures of the QUALITY engineering that went into them:
Nice cuts!

Great welds!

And excellent rust prevention!

While I was under the car, I ripped out the remains of the backyard emissions testing work-around.

The rear bumper was easy, its very easy to remove, and the supports were only held on with bolts.
The front, however, was less cooperative (Big thanks to my friend for cutting it out for me!):

While I had the front bumper apart, I decided I was going to "refurbish" the lights. I decided to start with the Fog Lights.
One Fog Disassembled:

Eventually I was going to run HID's in the Fog Lights, and being that HID bulbs are much longer (see below picture) than standard H3 bulbs, I had to do some modifications.

I had some old busted 190e headlights laying around, so I decided to steal some parts off it. I took the bulb "cover" off and hacked it up. On a headlight, it has prongs that extend outwards, I just trimmed them and bent them to shape. The result was a slight longer bulb "cover" which would work perfect for HIDs later:

One fog light done. I cleaned the glass, resprayed the inside of the surround. Polished the chrome reflector, and repainted the lens clips. The difference is minimal, but it will be all of the little things coming together which will make this car great. I am not leaving out any details. The result is a much brighter, more clear, newer looking fog light.
"Refurbished" Right

"Refurbished" Bottom

I'll finish up the other fog light tomorrow, and get the bumper back on and start with the headlights and corner lights. Until then, ENJOY!
Here is one of the headlights before:

And here is one of them after:

It was a rather rainy and dreary day, so I didn't any pictures of it back together. I will for sure have some tomorrow. I will also be installing some 6000K headlights and re-aiming both the headlights and fog lights. I will make tomorrows work a bit of a DIY for those who want to know. ENJOY!
Been working on getting the HID's in the headlights.
Spent a while trying to decide where to mount the ballasts.
I stole some brackets from my 2.6:

I cut and bent them until I had the right size and shape:

Repainted:

Installation location will be using the second screw which holds the fender on. It is a great place to mount them on these cars. Don't mind the gross engine bay in these two next shots:
With the ballast installed:
How it looks color wise. The bulbs it had in it when I purchased it were a very nice pair of H4s, and I thought they looked good and were pretty white, but they really don't look nice next to the HIDs.

Here's what the cutoff looks like, wont be doing any blinding of other drivers
:
I just need to get the wires from the ballast into the housings next, I can't find my drill battery to make a hole in the backing for the rubber gasket. I'll find it soon enough though, haha.
From there its onto the fogs! Look for an update later!
I started the day off cleaning up the HID wiring in the headlights. A few people have asked for me to be fairly detailed about this, so here it goes.
First off, I buy all of my HID kits from www.813motoring.com. NEVERMIND, as I just found out...I guess they are either going out of business, or changing their name. Now I am mad!
Well moving on from that, most HID kits are the same these days. Though they might be sold under a hundred different names and companies, there are only a small handful of actual manufacturers and they are all still very similar. Today, smaller ballasts are becoming popular. These are called "slim" ballasts usually. I would venture to say they will all be "slim" within a year.
Every HID kit I have seen has a small rubber grommet which the wires pass through. This is so the ballast can be mounted outside of the headlight housing, which is necessary. All of the grommets I have seen are the same size.
A 15/16 spade bit does the job extremely well.

Result:

You will likely need to use a 1/8th inch or similar drill bit to make a small notch in the hole to allow one of the connectors to pass through while still having a super tight fit with the grommet.

Here is the connector. This is the piece that connects the HID bulb to the ballast. The HID bulb is large, so the only way to pass it through is to remove the little clip on it. It just snaps on.
With clip:

Without clip:

Here you can see the need for the 1/8 "notch" in the hole as well as the removal of the clip. It barely passes through!

You can now pass through the Ballast power wires, and reattach the clip on the bulb wire. Then just pull the grommet through until it sits in the grove of the plastic:

Then you can connect the power wires. The ballast's power wires plus in to the connector where the old H4 light bulb used to plug in. The ground wire from the ballast (black) will plug into the ground on the connector, which is ground and the power wire from the ballast (blue) will plug into the power wire on the connector, which is yellow.

You may now clip the headlight backing back on, and hide the wires whichever way you choose to. The result is an HID installation that is not only very functional, but very stealthy as well:


Hope you guys enjoyed it, if you have any more questions feel free to ask!
Onto the fog lights!
Got the fog light wiring all sorted out.
This is where I chose to mount the HID ballast:

I had a hard time finding a good place. I wasn't sure if I wanted to drill any holes anywhere in the car, so I decided to use a preexisting place. I chose to mount it to an unused hole on the bottom of the headlight:
I used factory Mercedes mounting hardware I had laying around. I just slid the clip on the lip on the bottom of the light, and put the screw into there. No modifications needed. It is a good, secure, out of the way to place the ballast.
Once the ballast is mounted, you will need to drill holes in the same method described before for the headlights.
Inner cover:
On the outer cover as well:
The power wire from the HID ballast (blue wire) plugs right in to the existing power wire (which is mounted on the plastic bracket)
For the ground wire, you will need to do a little modification. The ground for a regular H3 bulbs come from the metal base in which it sits. The ground wire has a round plug in which it connects to the metal base. You'll need to remove the round plug, and install the flat style connector as shown:
Then its as simple as pulling the wires and the grommet through the cover as described before with the headlights.
Pull the wires through the outside cover as well. I tucked some of the wires and connectors within the outer cover. The end result is a very clean installation for HID headlights!
Hope you guys enjoyed! I'll have some more pictures later!
Headlights Only:

Headlight Cutoff:

Fog Light Only:

Slightly longer exposure (brighter) picture:

Fog Light Cutoff:

Headlights and Fog Lights:

Headlights and Fog Light Cutoffs:

Enjoy! Look for more updated tomorrow!
Last edited by SixSpeed; Dec 14, 2008 at 12:21 AM.
Sadly there hasn't been too much to report on recently. I have been extremely busy with the '86 2.3-16 getting it prepped and ready to go for paint. Been eating up all of my time.
I did start this project yesterday:

Should have both of them on tomorrow along with some new gaskets!
I got the freshly painted valve covers on, as well as some new valve cover gaskets. Just waiting on new Air Box Standoffs (forgot to pick them up at the dealer yesterday, DOH.)
I also got new plugs, wires, cap, and rotor:

This is much more like it!

All back together. The engine bay is almost looking somewhat presentable, haha.

I managed to run into a stockpile of European tail lights which were removed by the dealerships when grey market cars were imported back in the 80's. I picked up what they had. I paid a small fortune for them, but man do they look good! I will be putting a few sets on eBay as well.

Here is a picture showing the downfall of this SEC. The car had been repainted at one point, and poorly prepped. You can see to the left of where the license plate would be the paint is about ready to jump off of the car. Also, I was walking through my garage, and my pants caught the chrome corner piece and ripped it right off the car, lol. Oh well...Also, the rear window trim was taken off by the previous owner to replace the seal, and the job was never completed. I shall fix that soon enough.
Oh...at least the tail lights look good! :p

They flow SO much nicer with the euro spec front corner lights:

Enjoy!






