How to make a car, a legend with his own hands
This is not just any car, but the car is a legend with an interesting history - Mercedes 300SL "Gullwing". Below is a fascinating read about how to do from scratch copy of the legendary cars, and not just a copy, and the car assembled from original parts.
The process of creating a Mercedes 300SL "Gullwing" suspension of the Mercedes W202 and W107 has been used. Remember that the best - the enemy of good, put the adjustable dampers. Particular attention should be paid to the rear axle, normally with it having the biggest problems, which is why so customizers like beam axle. A Mercedes this unit together with actuators assembled on the stretcher, which is much easier to work with him.
Stainless steel exhaust system corresponds to the standard Euro 3 and the fuel tank - a work of art: the fuel is not lapped, partitions fitted therein and the overflow tube. On one of the photos - locking lock steering
The draft "Gullwing" was decided to use the next generation engines 3 M104 volume, 2 liters and 220 liters. from. paired with a 5-speed automatic sending. Engine choice was not accidental - it is more powerful, lighter and softer. Transmission primitive, with the torque converter, many of these units are familiar from Mercedes W124, W140, W129, W210. Power was also set, all new units, so that should be no problem.
Making the body.
Back in 1955 the company "Daimler Benz" produced 20 vehicles with an aluminum body and a composite. We decided to try the composite.
After making body and chassis assembly begins with the crossing of the body frame. The process is so laborious and tedious that no photos and the words will not be given. Assembly and disassembly, fit - all this takes more than one day. Many of the details are being finalized on the spot, and the body is attached to the frame through special demfiry bolts in 30 places. Install and customize any body parts - doors, hood, trunk lid. A lot of trouble with the glasses - they are mounted on rubber seals, as well as all original seals and are designed in stainless steel, it is necessary to adhere strictly to the thickness of the openings frames. Every detail is removed, adjusted manually and then set in place.
Many of the parts for the most popular rare model still produce small-scale in some departments than actively enjoyed by all the restorers. So that there is no secret, the plants themselves forge their rarities, especially successful in this "Audi" and "Mercedes".
Many museums are frank copies. So in recent years it has bred a lot of "Horch". This is particularly interesting, given that the entire factory documentation was lost during the war. Dozens of workshops on the equipment of that time stamp forgery, passing them off as thoroughly reconditioned products. The devil is in the details.
So we just bought and collected all the items that could decorate any curiosity over 500 thousand. Euro. I assure you, each Gadget and bolt (I'm not talking about the gum) are correctly marked in 1955. Original everything, even the seat rails.
Now and the body is primed, and is the most important point for the composite - in a special paint material, because there need plasticizers, and all sorts of other complicated things. primer cherish secrets and no one will ever tell them not to. But it looks nice.
In the meantime, the body is painted, let us prepare units for assembly. As I have already said - the devil is in the details, and them in the car for more than 2 million! The instrument panel, it searched for a very long time.
priborchik and relay also find, of course, not all turns out right.
But with enviable patience and perseverance you will be able to get a fully authentic instrument panel consisting of 80 (!) Parts.
The main thing is that it then also earned: priborchiki-all expensive. Cheap good does not happen.
The body is covered with 6 layers of lacquer, it is very beautiful and do not have to be a film chrome paste. Yes, shagreen - is necessarily, and of the grain, so that was fine. Now already do not paint, everything is diluted with water, the environment they have, cherish nature. Incidentally, the ink 744 (Silver) - the most difficult to paint you any painter will tell.
to get married finally chassis with bodywork.
Install the door. It would seem that it's not tricky, but I want to tell you a story. Mercedes 300SL "Gullwing" had many structural defects. One of them was in fact the door: they were steel, heavy hinges, and fastened to the roof of the body, and fixed spring enclosed between the hollow steel tubes with hinges at the end.
In the uppermost position, the spring has been compressed, and the door rattled stretching slams the door when lowered. When opening it was necessary to overcome the resistance of the spring, which is just pull the door together with the brackets (at 900 euros per share).
Experienced owners "Gullwing" know that the inability to use it will inevitably lead to deformation of the roof, besides themselves brackets simply break down. Rod with a spring assembly eventually became a rabid deficit and its cost has risen to astronomical heights. Every owner of such rarity repair these units once a season. We decided to go the other way and put gas shock absorbers.
It would seem to be easy, but there it was. We had to develop a whole unit, it took 4 months of hard work. Fortunately, I found a workshop embodied ideas and drawings to life. At full authenticity external doors now open the rear fifth door in the German SUV. Node to be so successful that it immediately became the object of desire of all owners of rarities, I think that soon all "gulvingi" will have very effectively and smoothly, without knocking the door. Now this process was like a stroke of the wing gull - gracefully and smoothly. This is just one, and the simplest example of the challenges that had to be solved in the construction of the car.
By the way, the door lock mechanism also underwent changes. Despite the cost of 1500 euros, it is very often do not have seized and fixed the door, but that's another story.
In the beginning, the project seemed to be trim - this is a small problem, the benefit at every turn workshops Altering salons, so that it and the skin is now handle any master. Business then - to sheathe bunch detalek skin, but as it turned out, this is a huge problem!
After four attempts to create the interior details in tuning studio, I realized that everything is much more complicated.
Create products well, we did not want to look like the original. It looked cheap imitation: the skin puffs up, were visible signs of heat treatment, the invoice does not match, and the stuff no one could guess. In short, I began to delve into the intricacies and found that modern masters did not know how to work with felt, wool and other materials used at the time. They stupidly heated and stretched skin foam used wherever they could actively worked iron, in short, mercilessly destroying materials, depriving them of their naturalness and nobility. I also do not speak about longevity.
Tormented for six months, we have come to the conclusion that only the restorers are capable of such work. They and a special foam and felt. In general, the company found, guys - wolves, guys, under 60 years, who has 40 years of restored only Mercedes. What they showed us and told - it's just a novel about the skin, and they guard their secrets about the same as the secret of making paper for a dollar.
Interior details on my baby do 4 months. Skin just like a living.
I will add, that is the skin, which now offer manufacturers - this is bullshit chemical impregnated. No wonder all owners of Mercedes and BMW, after a year of operation ofigivaet - interiors look like old redvanov: stale, the skin is pulled, peeling off. As I said earlier - the devil is in the details.
I'm not talking about vinyl, widely used by the Japanese, and all the producers in principle. Now Mercedes leather jacket and not enough bullshit one, so there are options - "designo", "individual", "exclusive". Leading manufacturers even for $ 10-15 thousand. You will be offered a real skin, and what you sew 50 thousand. Rubles, even skin not dare to call.
Wheel - one of the most important parts of the car. So there are two types of wheels for our handsome. First staged in the civil version.
The second offered as an option. They came out of the sport - the real thing, the central nut. Of course, to have a beautiful chrome wheels, but also the price of 5 thousand. Euros for the wheel a few annoying.
How then thrash hammer on the nut, knowing that it is gold? The original drive for the classics, too, is not cheap - 3 thousand euros.. So I think, is sick wants to 8 thousand. Euro save.
One of the main factors is the removal of engine exhaust gas (combustion product). I do not want to recall here the laws of thermodynamics, I can only say that the past 150 years, the exhaust pipe is a symbol of progress. Recall locomotive pipes, ships, blast furnaces. Remembering my love for detail, I want to assure you that this pipe was given the highest priority. It is a masterpiece of engineering.
The exhaust system is made of stainless steel, which can not afford any manufacturer, and is a complex system tolkostennyh and thin-walled tubes mounted one inside the other, it allowed the full authenticity of the appearance of the tube to solve the problem "gulvinga" - noise, passenger compartment heating. And the main thing - it's the sound of the exhaust, it's just a song. The problem has been solved by using resonators mounted within the system. Do you want to understand what your car is - look at the exhaust pipe!
At the date of the photo does not pay attention, just bought a decent camera down. Here otschelkali only instruction not figured out to be not that date.
We made a lot of changes in design, do our best to do everything authentically. Very clever handbrake.
With the tank is another story, its made of stainless steel, slightly modifying the location of the neck, but that's another story.
There is a saying - it is better to see once, than hundred times to read about it. My favorite expression, which I have often repeated, - the devil is in the details. It is these details and I'll show you. It makes no sense for a long time to write, you'll understand.
Wiring harnesses and braided, well, this, I think you just have not seen a two-tone horn, in short, just look at all this and called TECHNOLOGY.
The main task confronting the implementation of this project was to create a complete authenticity of all the interior details. It would seem that could be easier than to copy the sample is available, but as they say, is not so simple, and much harder than even restore.
So, we had to make it work all analog instruments, and to work properly with the electronic components of modern machines; stick in a tight little car a bunch of additional equipment such as air conditioning, power, power brakes. All this is supposed to work on the staff of toggle switches and switches. Stove damper before had a mechanical drive as on the Volga GAZ-21, because it was necessary to alter fundamentally and stove. But the biggest problem was the production of the gear selector switch.
All the difficulty lay in the fact that the car was originally built for the sport, was small and very low, even the engine had to be placed at an angle of 30 degrees to the silhouette of the machine is not broken. The box was located in the tunnel and had a direct pivot drive.
between the box and the box itself was no more than 2 cm of free space. I have already said that the machine itself was cramped and very noisy, it was necessary to solve this problem. Since the standard was taken a couple of engine-gearbox, the task has become more difficult, because the automatic transmission much larger in size and has a very different management principle.
After much anguish was designed hinge and rod system, will fully simulate the assembly, as is easily seen by looking at the original source.
And the most interesting thing: if you peruse the photos, you will see that the seats are much lower than the original, it is also cunning. The fact that the car was so tight that the person with the growth of 180 cm. Rested his head on the roof and was forced to sit hunched over at the helm, I love to go on the straight hands, because it was necessary to change the angle of the steering column to provide comfort and disrupt the overall look. How this was achieved - it is a novel, beginning with the production of unique slide down to reworking the floor and seats.
I'm not the first who decided to recreate the legendary car. Back in the late '70s in America were made similar attempts, the furthest advanced Ostermaer Tony, a former mechanical engineer from Gardena. He managed to build over 10 years around 15 vehicles with units of Mercedes cars of those years. Today these machines themselves are rarities.
I've seen them, of course, this is not such quality products as we would like, but it is the best that has been done. In the 90s there were attempts to "Speedster" American company, using a matrix Tony, implanting it into knots "Chevrolet Corvette C3". 2 was produced only vehicle. One of them is now in Ukraine, and the other in Moscow. The machines were sold at 150 thousand dollars.
In fact, that's all. However, there have been attempts to put on a shell on SL and a lot of loud statements, but it is zilch, people fled ahead of the engine, both with our e-mobile: still nothing, but already 40 000 applications submitted.
By the way, working with the composite is very complicated. Only its quality painting is worth about 10 thousand. Euro. And most importantly: to forge and copy - are two big differences.
It is said that in the car everything should be fine, and the engine and the trunk. In the first car we decided to use gas shock absorbers for opening and locking the boot lid.
We have altered a little filler neck, reasonably believing that if it is sealed to the boot lid, it will reduce the risk of spreading the smell of gasoline inside the car in case of spillage.
I did not like the idea. On this machine, made closer to the original, changing only the shape of the filler neck (steel funnel around the lid should prevent fuel spillage on the Carpet).
Of course, without the collective farm has not done: built a leather hood around the filler neck. Like looks beautiful, and abandoned absorbers placing native mechanism (stick) fixing the tailgate. One could of course zamorochitsya with springs as on modern machines, but I think it would kill the very spirit of the car. It looks wonderful trunk open.
Yes, and the rear is very nice it looks. Given that it is now all use tubeless tires, we decided to free up space by placing in the boot dokatku instead of the standard wheels. Now though there is much to throw a string bag.
In fact, the case moves inexorably to its logical conclusion. It was nice that everything is so quickly over, and left pomazyukat movilchikom prilyapat wheels.
Wheel of Time, not to ugvazdat original.
That's basically it!