O'erlanderwagen build

[mk216v]

So as many of you know, my 1980 300GD "RadioFlyer" found a loving home with new friends in Seattle (W123 Mercedes and FJ60 Cruiser aficionados). It was sitting in my garage too often, and I couldn't bring myself to put a 606A in it (617A is still too slow for me), so I decided to sell my 3 vehicles and just purchase 1 newer G500. I had really hee'd and haw'd over this decision(vs finding a late Europa truck), but thanks to the advice of many G veterans here, it made more sense to pick up a well-loved MBUSA W463 and just build it up.
Pics of RadioFlyer, I do miss it!
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After searching and searching and searching for a Pewter G500, I gave in and went with my 2nd color choice, Tectite Grey(I had this on my '03 E55 and loved it, but I was aiming for Pewter to show less dust/dirt. Oh well). I got very lucky and found an original Oregon '03 G500, which had spent only the last 2yrs garaged in New Jersey. It had been impeccably maintained, lowered with Brabus dampers/springs so that it'd fit into the owner's garage.

Pics of when I found it;
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Coming off the transporter;
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The first order of business, besides re-inspecting the truck maintenance-wise, was to de-bling it. This was my biggest gripe with an MBUSA truck--too much wood, chrome, shiny stuff.
I had the G500/V8 badges removed, removed the factory stainless/polished brush guard, disassembled it, removed the horizontal light grilles for good, had the brush guard blasted and powdercoated in satin black.
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As I did on RadioFlyer, I had one of the body shops lightly smoke the front turn signals, rear signals, reverse light, and mirror blinker lights(don't try that one at home kids. The cheap ***** plastic that MB uses allows the securing clips on the back of the $400/ea mirror glass to break, and then even pro-grade glue doesn't keep them on and allow them to be clipped back onto the mirror, so I had to glue the glass right onto the mirror motors, eeeek!).
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I had the chrome strips sandblasted off the front grille and front grille repainted Tectite, the front star blasted and painted satin black, the 4 side reflectors painted Tectite(bulbs removed--I was going to use resistors to emulate the bulbs, but since they'd get hot, I'd rather not catch the truck on fire, so I'll just disregard the front bulb errors as the car doesn't care about the rear bulbs for some reason).
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[mk216v]

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Since I will be using this vehicle as an overlanding platform, I've been laying out plans for awhile, and accumulating parts here and there.
I picked up a slightly used Autohome Columbus Variant roof top tent (thanks SteveSmith's bro Barton!) from NorCal, and had it painted Tectite to match.
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Got a FrontRunner 2.4M Tall roof rack and Fiamma F35Pro 2.2M(special order from Italy, thanks Serpe!). I disassembled the Fiamma, had the shell powdercoated satin black, and painted the end caps satin black too to match. Do you see a prevailing theme here?
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Other overlanding goodies have been arriving for the inside and outside of the truck as well.

Since I needed more ground clearance and springs capable of heavier loads, I decided on a set of Koni Raid HT's and OEM Red3stripe front springs and Brown2stripe rear springs (thanks Mario and Guido for the help, and of course Jon with the install!).
Installing the factory spring rubbers was difficult at first since we used glass cleaner and a rubber tipped air nozzle. However, thanks to Minh's tip about a bit of engine oil, the fronts went much easier. Due to the tight windings on the front springs, they would have been incredibly challenging with the glass cleaner method.
The ride is firm but certainly not jarring, and best of all, I gained about 2" over the Brabus susp! It's the perfect amount of lift for me.
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I'm having custom Shockwear covers made to keep the front shock shafts nick-free.

[mk216v]

Before w/ Brabus susp;
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After w/ Koni and OEM Red3/Brown2's(I also removed the factory running boards which helps with the beefier look. Karl's sliders will come later.);
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I also had the front windows tinted to match the rears, and new clearbra installed on the front of the truck, foglights, roof top tent. Tommy's did an awesome job. Now we're getting somewhere.
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Last order of business was the goofy OEM side trim(what were the Mercedes bean counters thinking with the 80's style trim?). I stumbled upon some uber rare special side trim(thanks Chris!!) which I installed. I think it really finishes the exterior off well for now.
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Hutchinson beadlock's have arrived, 285/75/16 E-load BFG AT's arrive later this week. I hope by this weekend I'll have those 5 mounted on the truck, factory tire cover cap removed. I'm really excited to see what they look like on the truck.

Next plans are to work on the interior; mount the National Luna fridge(thanks Paul/Equipt for the impeccable service!!), custom laptop mount, custom rear cargo platform, etc etc.

More to come....

[ChuckB]

Let me be the first to say congrats and nice start! I like all of the de-blinging that you have done and like the Tectite Grey. I'll be watching your build closely.

[mk216v]

Let me be the first to say congrats and nice start! I like all of the de-blinging that you have done and like the Tectite Grey. I'll be watching your build closely.

Thanks very much Chuck!

[traveller09]

Awesome! We are of like minds, I will be watching your build closely as well.

[Ryanmb21]

^^ Looks great, can't wait to see it with the new tires

[mk216v]

Thanks! Like minds think alike.

[RBA]

Real nice dude! Keep an eye on those Koni's...mine sucked. 1 was busted on delivery and then I blew 2 within 9 months.

[mk216v]

Real nice dude! Keep an eye on those Koni's...mine sucked. 1 was busted on delivery and then I blew 2 within 9 months.

The Koni Raid HT's(90's)? Sorry to hear.
I know a G55K owner who wheels a lot with them and he's been very happy, so have a few others. One G500 owner had 1 or 2 that were **** off the bat. I believe they have a lifetime warranty though and thankfully they're not as much a PITA to install as the longer springs, so I suppose if one leaks or blows, it can be replaced fairly easily.

I was disappointed that Bilstein didn't have anything beefier off the shelf. ORC has some built Bilstein's, but I couldn't find anyone else running them so decided to try the Koni's.
ORC's Fox coilovers are way overkill for me. I like OEM engineering.