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G Class (W460, W461, W463) Produced 1980-2018: 290 GD, 290 GDT, 300 GD, 350 GD, 500 GE, G250, G300, G300 DT, G320, G500, G550, G55 AMG, G63 AMG

2002 G500 build/ restoration/ conversion photo thread

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Old May 23, 2016 | 12:07 PM
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From: ToRonTo, OnTaRiO, Khanaadah
s550
wow...this car is going to come out nicely. can't wait to see the finished product.
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Old May 23, 2016 | 12:16 PM
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Thank you. The plan is to have it finished in 2-3 months.... (that's the plan at least)
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Old May 23, 2016 | 08:57 PM
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Installed rear rotors and calipers.



















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Old Jun 1, 2016 | 10:03 PM
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Cleaned, sanded, decreased, primed and painted the front end before the fenders go on.











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Old Jun 3, 2016 | 12:37 AM
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Assembled some front end bits today. New radiator brackets and new hood latch.
















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Old Jun 10, 2016 | 03:19 PM
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2011 E550 , 2006 G500
You definitely know your way around a wrench! Keep the pics coming.
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Old Jun 10, 2016 | 05:20 PM
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Thank you
Grew up helping my dad in the shop and learned allot : )
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Old Jun 15, 2016 | 01:12 AM
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Installed passenger side G63 rotors and calipers on my G500. After searching for brake wear sensors, I found a set from Dodge Sprinter, they fit G63 brake pads and plug perfectly in to G500 brake wear cable. Brand new ABS sensor as well. Had to modify the plug on ABS sensor to work with G500 plug that's on the harnes.

Covered calipers to avoid any scratches or chipping.

Stock G500 wheels did not fit, so G63 wheels had to come out of the storage





















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Old Jun 17, 2016 | 12:37 AM
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Driver side rotors and calipers went on today. Cleaned exhaust heat shield's. Working on attaching the G63 AMG exhaust system.

























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Old Jun 18, 2016 | 04:53 PM
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Working on cleaning, restoring and painting exterior door handles.























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Old Jun 26, 2016 | 02:56 PM
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Painted and assembled door handles.

















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Old Jun 30, 2016 | 07:34 PM
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Great work!!
Great work! What paint did you use on the handles?

Originally Posted by Kobzarhomes
Paint
ed and assembled door handles.

















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Old Jun 30, 2016 | 07:42 PM
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This is what I used:
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Old Jun 30, 2016 | 07:46 PM
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Cool!! Thanks for the info!! Appreciate you posting your progress. All the best!
Originally Posted by Kobzarhomes
This is what I used:
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Old Jul 18, 2016 | 02:06 AM
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Took the running board brackets to sand blaster. Tried cleaning one by myself but too many angles so I gave up.

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Old Jul 21, 2016 | 10:56 PM
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Painted the running board brackets after getting them sandblasted

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Old Jul 21, 2016 | 11:03 PM
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Installed exhaust on the passenger side. I kept the header flange stock and welded G63 exhaust to it. To hide the weld I used "titanium header heat wrap". I think it came out looking pretty nice 👍









All new oxygen sensors (front and rear)



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Old Aug 11, 2016 | 01:20 PM
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awesome project. Looking good
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Old Aug 11, 2016 | 01:25 PM
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Thank you
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Old Aug 12, 2016 | 02:09 PM
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2011 E550 , 2006 G500
Im surprised you started with a G chassis to begin with. At this point I fully expect you to form your own frame and stamp your own body panels using average tools in your garage.
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Old Aug 12, 2016 | 02:16 PM
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G wagon is a fairly simple and basic construction vehicle. You don't need fancy tools to work on it. 👍👍
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Old Aug 12, 2016 | 02:21 PM
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Yesterday I test fitted the front end parts. Everything fits perfectly (few tweaks were needed but no sweat). Almost ready for paint.




Last edited by Kobzarhomes; Aug 12, 2016 at 02:29 PM.
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Old Aug 12, 2016 | 02:26 PM
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Created a custom reinforcement bar to keep the end of the bumper from jiggling around and aligned with the fender.

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Old Aug 21, 2016 | 11:03 PM
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How does the G63 exhaust sound with the 5.0? Loud?

Also- looks like you did the G63 downpipes in addition to mufflers, correct?
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Old Aug 21, 2016 | 11:07 PM
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Haven't had a chance to start it up with G63 exhaust, left side is not on yet. Hopefully within next week.

Yes, it's a full exhaust, from headers out.
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