Rebuild of a 1980 G

[Joe]

Hi,

currently I am rebuilding a 1980 built G (460). Instead of the 240d engine a 300d is being installed from this blue one,
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_2010_10_G_IMG_3651_1.jpg


only the two rear fenders had bigger problems and were exchanged
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_2010_10_G_IMG_3675_1.jpg


and that’s it more or less. The chassis is completely stripped
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_2010_10_G_IMG_3678_1.jpg


rust-stop paint and than protection tar sprayed onto the ground plus ~ 4 kg Mike Sanders fat sprayed into the struts of the cabin,
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_2010_10_G_IMG_3679_1.jpg


here after spraying it with rust protection paint,
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_2010_10_G_IMG_3681_1.jpg
(NB: On the photos, that’s not me but my friend who helps me a lot.)


Motor and axles are removed:
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_kIMG_3682_1.jpg


5-speed Getrag Gearbox fits, clutch is OK, just one bearing needs to be replaced:
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_kIMG_3691_1.jpg


2 break tubes I asked another friend to replace although he said that the new ones will look the same after one year – but now the access is much better than assembled.! Rear and front axle are mounted. The front brake is lacking still the saddles, hope to pick them up today. Of course all felxible hoses were replaced.
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_kIMG_3696_1.jpg


In total 2 layers of filler-paint, although you think now it is OK you still find places to improve.
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_kIMG_3697_1.jpg


OK, we didn’t paint the G in the design version „waterfall“. You don’t know that? Mix the paint so that it is not a little bit stiff at all and leave the airbrush long enough on a spot, together wit blue background and white spots you will have a 3-dimensional waterfall impression.
It was painted as Big Foot in sand yellow RAL 1002.parts.
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_kIMG_3701_1.jpg


From Monday onwards I hope that axles, engine, gearbox, exhaust system etc. are completed till end of next week and the latest on Saturday the cabin will be lifted onto the frame. I am looking forward that my friend will have time available to finish the paint job at the other parts.
NB.: Normally I am more active in the MB-truck part of this forum.

[bitoy]

Good luck on your restoration.

[Jnich77]

Wow, thats one heck of a project! Looks good man.

[Storz]

Incredible

[stevegsmith]

Very cool! Keep on keeping on!

[Joe]

Hi,

since beginning of this week the engine is back in:
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_kIMG_3729_1.jpg

The cables in the interior are fixed again, the steering mechanism is mounte etc.:
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_kIMG_3730_1.jpg

some of the interior fixed again, rear bench, ...
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_kIMG_3732_1.jpg

The Recaro seats are cleaned from the bird's ****, vacuum-cleaned and treated with carpet spray. Once the dashboard is back in the seats will be installed:
http://www.allrad-lkw-gemeinschaft.de/phpBB2/userpix/44_kIMG_3742_1.jpg

[4xdog]

Great job! It's super to see old iron being well taken care of, and an interesting vehicle continuing in service. Looking forward to your completion of the rebuild.

[Joe]

Hi,

so, so finally I found the time to integrate the G-Story into my HP, the update is now online. (http://www.gertenbach.info/e_big_foot_54.htm)

http://www.gertenbach.info/images/Big%20Foot/Big_Foot_54/2010_G_073.JPG

[mk216v]

Keep up the resto Joe. It's great to see an old truck revitalized!

[oryxexpeditions]

Very nice. Love that color too!

David

[basharatu]

Good going, Nice project!

[4Rescue]

Beautiful work mate... Can't wait to see the finnished product eh.

Cheers

Dave

[otiswesty]

Wow, great project. Very ambitious.

[Joe]

Hi,

thx to all of you for your kind comments.

The final jobs were finished in time and so I was able to organize a license-plate valid for 5 days. The first destination was Mercedes in Bad Kreuznach, where the emission test was made plus the brakes. With these 2 documents I drove for the TÜV-test plus testimonial for historic cars. Both the G passed without any problems and so a regstration as an "H"-car (=historic) was possible. Due to the official definition the G is now in a good condition and is a cultural artefact of the automobile aera.


http://www.gertenbach.info/images/Big_Foot/Big_Foot_54/2010_G_086.JPG
http://www.gertenbach.info/images/Big_Foot/Big_Foot_54/2010_G_085.JPG
http://www.gertenbach.info/images/Big_Foot/Big_Foot_54/2010_G_084.JPG

[kerry]

Wow, that's one heck of a project. Curious on one point; with all that work, why not install a 617 turbo engine instead of a naturally aspirated one?

[mk216v]

I hope you can find a garage to store it in Joe. Shame for the new paint to become weatherized.

[Johnny Christensen]

Wow, that's one heck of a project. Curious on one point; with all that work, why not install a 617 turbo engine instead of a naturally aspirated one?

Since the G never was offered with that engine, I think it would not be possible to register as an historic vehicle.
Then you may get into all kinds of high annual fees due to pollution, if you go for ordinary vehicle status.

[kerry]

Thanks. Interesting explanation.

[Joe]

Hi,

in Germany the regulations allow any modificiation which was available within the first ten years after the car was built. So for a car built in 1980 you can install anything which was availabel till 1990, newer parts will most likely sacrifice the "H"-status.
So, yes, a turbo is an option I am thinking about but not now. Too much money already went into that project and another EUR 5k or so is not affordable at the moment.

And of course thank you very much for your kind comments.

[stevegsmith]

Nice job Joe. Very cool to see a project completed so quickly. Thanks for taking the time to post.