Mercedes W211 e320 “rally build” (1 Viewer)

[coleAK]

I have been on mud for years. In the last >30 years I’ve had a 60 series, 80 series and now 200 series since 2013. We have also owned a 2004 MB e320 4matic we bought new late 2003. My wife drive it for 15 years now my teens drive it. Anyway this past fall my daughter (who usually drives her Colorado) was in the MB and got too close to a parking block, taking out the lower front trim, radiator, condenser, fog lights, radiator mounts,….

Unable to find many of the plastic parts (apparently MB only supply’s many parts for 10-15 years now…) I thought of other options and posed the question to the 200 series group about building a skid plate. The build turned out well so I though it my help others to do a build thread. Here you go.

 

[coleAK]

Initial damage. Took out pretty much everything below the main number frame, passenger side fender liner, and passenger side radiator mount (driver side was repairable).

 

[coleAK]

My daughter did almost all of the tear down and repairs (with my oversight and direction). Replaced the radiator, hoses, condenser (parts from MB), and I found a radiator mount from a salvage yard. Her hair in the top picture

 

[coleAK]

I could not find the lower plastic bumper cover, lower fog lights, lower air dam, and air baffle. So had this idea to do a skid plate and rally lights. I made a cardboard model then drew it out.

 

[coleAK]

I debated learning to weld and making my own skid plate but decided that may be a skill I learn later. I found a metal shop with a “short wait”, It took 3 months but it turned out great.

 

[coleAK]

Last step (for now) was the lights. With the ORM fog lights gone I wanted to use the OEM switch, relay, fuses,…. Did some research and figures out they are 55w lights. Figuring 12v 55w lights are equal I found 12v 55w Hella 500 FF to use. I’ve messed with the switch electronics in this e before and know MB has some oddities (over engineering), so I wanted to do as little work to the OEM wiring as possible. So I took the bulb out of the fog light bulb assembly in order to fabricate a plug that would plug into the vehicles fog light bulb receptacle. First I used clips to test that it would work (I did) Then I soldered the wires from the hella lights into the bulb housing. Top picture is the bulb with the bulb removed.

 

[coleAK]

Next I had to make an extension of the Hella wires (red and black in picture) and soldered the modified bulb to the end. Essentially making the Hella lights into the new bulb, as far as the MB is concerned.

 

[coleAK]

Now time to mount the lights. I modified some deck brackets from Lowe’s and used the existing head light bracket holes/bolts) I used to attach the skid plate. I also tucked the side running lights with zip ties behind the skid plate, still well visible from the side when on.

 

[coleAK]

Lights installed, leveled, cleaned up and working. Last step probably when it’s due tires is I found 3/4” spring lift/spacers I’ll likely put on them up size to a larger tire size.

 

[lx200inAR]

Looks awesome. Is there not enough mount points to cut the bumper in half and just use the top half to cover the gap from the lights tot he new skid? A la 200 series bumper cuts for aftermarket bumpers. I see now it's pretty beat up along the passenger side, but there's maybe enough there to fill a lot of the gap.

 

[coleAK]

Looks awesome. Is there not enough mount points to cut the bumper in half and just use the top half to cover the gap from the lights tot he new skid? A la 200 series bumper cuts for aftermarket bumpers. I see now it's pretty beat up along the passenger side, but there's maybe enough there to fill a lot of the gap.

I considered that for a min, most of the mount points are along the bottom. I didn’t look att that closely at it though. And don’t want to cut up the current bumper until I got further along. I may give that a try in a few weeks, Cheers!

 

[D21FJ60]

Love it.
In the dc area there are tons of w211s for dirt cheap available for parts. Can imagine it isn’t this way up there

 

[coleAK]

Love it.
In the dc area there are tons of w211s for dirt cheap available for parts. Can imagine it isn’t this way up there

There are a lot on the road, but very few for sale. And clean ones sell for $6-10k. Heck clean w210’s sell for $5-7k. I found a few salvaged ones but all had front end damage.

 

[coleAK]

Looks awesome. Is there not enough mount points to cut the bumper in half and just use the top half to cover the gap from the lights tot he new skid? A la 200 series bumper cuts for aftermarket bumpers. I see now it's pretty beat up along the passenger side, but there's maybe enough there to fill a lot of the gap.

After you mentioned this. I thought about it more. Between an angle grinder, epoxy, zip ties, and some Bondo. Made it work. Now I just have to figure out how I’m gonna attach the rally lights back on.

 

[lx200inAR]

After you mentioned this. I thought about it more. Between an angle grinder, epoxy, zip ties, and some Bondo. Made it work. Now I just have to figure out how I’m gonna attach the rally lights back on.

View attachment 3879800

View attachment 3879801

Looks great.

Maybe some kind of c channel that could wrap under the lower lip and mount to the same place they were before, just spaced out front of the bumper.

 

[coleAK]

Looks great.

Maybe some kind of c channel that could wrap under the lower lip and mount to the same place they were before, just spaced out front of the bumper.

I think I have a pretty good idea on how to put them on. It’s not all that high on my priority list though since it won’t be dark again in until sometime in September.