Newbie with BIG ambitions
hi all this is my first post, ive recently dipped my toe into the world of the G, ive bought a 1987 280 auto. however its been badly converted into a 3,0 diesel manual, all the electrical systems dont work so ive stripped it all back and started again with an after market fuse box, im also face lifting it to late w463 spec.
Welcome mate!
Please feel free to share the project, lots of good advice and help here,
Raj
the interior was a proper mess
NOw there is someone on a real mission! Gonna look great when finished. Will it be a 'soft roader' or you going to take it off the black stuff?
Spider1V
Hello
Good luck with the project and keep posting photos of your progress
Hello and welcome to this pool, hope the dip was not too cold. Keep up the updates.
The G will not be a trailer queen, I'm gonna use it to it's max potential, I know face lifting a G is not to some people's taste, but I want to do it, I see it as a challenge. Here are some more pix
I'm getting the funny feeling that some people aren't happy with me using an aftermarket fuse box module, the reason I'm going after market are:
1. The original petrol/ auto loom had been bodged and did not work.
2. An aftermarket system is much cheaper - and is more straight forward.
3. I had a lot of unused wiring in my system and it was far to confusing for me to bodge the bodge.
4. Judge the aftermarket system once I've finished. I guarantee it will be simpler, cheaper, more reliable AND neater than the original Merc fuse box
http://www.cbsonline.co.uk/mobile/product/CBS_12_Circuit_Wiring_Module_W...
this is a link to the fuse module that I'm using, it's a very good quality product
Very Interesting. I didn't know that it was possible to buy an aftermarket fuse box. I agree though, the exisiting fuse / relay box even in a 91 463 300D is a terrible layout...
Is it a straight swop out for the aftermarket - just rewire exisiting wiring to new box ? Surely can't be that easy.
Best of luck with your project anyway. If your going for it may as well go big. 
So has anyone ever wondered how you get w463 headlamp surrounds onto a w460 wing? Well here's my attempt, basically I have taken a stock w463 headlamp surround (OEM) And I've drilled a 5mm hole in each mounting lug. I then inserted a 5mm bolt In each lug and held them in place with chemical metal, this then gives you two threaded studs protruding from the lamp surrounds I then did some measuring and drilled two 5mm holes into the front wing, just above the lens 1. Insert studs into holes 2. Secure with nuts from inside the wheel arch (not too tight) 3. You now have w463 headlamp surrounds :)
In order to fit the "hockey stick" trim panels to a W460 the panels need to have the mounting lugs cut off!! Yes just like you I hate the idea of cutting up something that's brand new.
Oh well... looks like you managed it in the comfort of your kitchen ;J
Seriously, you seem to be pretty handy with this re-build game. Parts aint cheap. Keep the photos coming.
One of my biggest electric issues was that the engine did not shut off on the key, I had to either stall it or manually press the shut off lever or suck!!!! On the vacuum hose goes to the diaphragm On the fuel pump. The previous owner had the vacuum solenoid rigged up to a bunch of relays. I took the solenoid out and played with it on a bench with a battery and a hand operated vacuum pump, I worked out which inlets/outlets were connected to each other with power on and with power off, I've now rigged it up with NO relays and the power source comes from (ignition on) So when it turn the key on the solenoid closes. When I turn the key off the solenoid opens, exposing the fuel pump diaphragm to vacuum and the engine shuts off, simples!!! The guys who put this 603 engine in were cowboys, I'm dead chuffed I've fixed this critical electrical issue Attached is a pic of the solenoid correctly plumbed in.
I managed to get the headlamps working today from the combo switch I also got the rear screen working too, almost there Below is a pic of my old headlamp surrounds, this is another reason why I'm face lifting to w463 parts
This is the new fuse box in its new home, all the systems have been tested I just need to bring in the wiring loom neatly
Welldone Jimmy,
Your methodic work ethos shows in the tidy crimping you have done to the wiring on the fuse box - excellent keep it up.
This is the W463 facelift parts sprayed lacquered and ready to go on.
and as an added bonus I also now have a Mercedes brilliant silver kitchen work top
These are on E bay Germany at the moment
http://www.ebay.de/itm/Kotflugelverbreiterungen-5-cm-Mercedes-G-/330893172704?pt=DE_Autoteile&fits=Make%3AMercedes-Benz|Model%3AG-Klasse&hash=item4d0ac51fe0
might be able to clean then up
or if you have deep pockets ...some original 463 ones....
http://www.ebay.de/itm/g-klasse-w463-kotflugelverbreiterung-satz-vorne-h...
Steve
At that price....with a bit of work i'm sure you could make a good job of them...i'm just wondering how they would ship. But GRP is easly repaired/re-enforced. coulpe of layers of kevlar on the back and you could have ballistic arches.: )
Steve
Wow so my G has left my garage for the first time since January, it's slowly coming together
Do you drive upside down in Ipswich ?
Maybe he's Australian?
Some great work there Jimmy! Would hate to get in a room with you Axel, PXW and a few other members......you would be stripping things down and rebuilding them again! (probably better than the original 
)
Keep up the good work
Spider1V
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this is it the day i bought it