Rust Bucket

Puch-G Without Fender, Grill, and Bumper

The early W640 G-Wagons are prone to rust. Starting in the early '90s the factory started doing a much better job with rust prevention of the body and frame but those of us with early models must use wax behind the body panels to fend off the ravages of rust.  Even then, after years of water and for trucks in snowy environments, road salt will take a toll on the bodies.

My truck was starting to show some signs of rust, so I found a local body shop that specializes in auto restoration and dropped off my Puch-G.

After the inevitable "wow that is a cool car" they asked what I wanted to be done. I told them that I was not looking for a show car, just to get the rust under control and get it protected so I can drive it around without worrying about the body acting like a sugar cube in a cup of coffee.

G-Wagon Rust Repair

I stopped by 3 days into the work to give it a quick look over. They are doing a fine job cutting away the rust and welding in new metal. From what I can see it will be good as new in no time. Check out the rust that was cut away from behind the front of the wheel and the correct way to weld in new sheet metal.

I'll keep you update with the progress as work continues. 

Heater Fan Motor Replacement

When I was doing the test drive for my Puch-G I noticed the cabin fan did not work. "No big deal," I thought to myself. - it is probably a fuse or a defective switch. Even if it was the motor, I had replaced cabin motors in my MG-B and Jaguar MKII so how hard could it be?

Some quick troubleshooting with a volt-ohm-multimeter confirmed the switch was getting power, working and it was probably the blower motor. So what if it needed to be replaced, no big deal because I've done it before. I was right... and wrong: replacing the motor is very easy, getting to it, not so much.

My Puch-G is an old Austrian Military G from 1991 and since it was a radio truck, it features a 24v electrical system so when I called Sean at EuroTruck Importers and he said he had a Bosh 24v motor PN 0130007004 in stock I was worried that it would be hard to find later so purchased it for $135.

That Bosh blower motor sat on the shelf for almost two years before I got the nerve to replace it. Asking around about replacing the motor, everyone said it was no big deal, "you just have to pull out the dash." After three days of work, I'm going to tell you not only do you have to pull the ENTIRE dash, trim, glove compartment, gauges, vents, handle, center console, steering wheel, windshield support (my windshield folds down), switches, turn signals, heater ducts, metal dash, and the heater. You see the cabin fan sits in the middle of the firewall between the air-intake and the cabin.

It is not hard work, it just takes a LOT of time. I'm not going to go through the process step by step because the W460 G-Wagons were made for well over a decade and military versions like mine even longer. So dash configurations differ over the years. What I want you to know is that the process is not hard but is time-consuming. Easily done by anyone with medium skill level and simple tools.

As you start pulling the car apart, follow these simple rules:

• Remove the negative connector from your battery prior to doing anything.
• Take photos as you go to document where everything goes.
• Mark the screws and bolts so they go back to the correct place - poking them into cardboard with Sharpie notes works great.
• Don't force anything, most parts come out easy, so if it is not coming out, look for more screws.
• The flexible ducting will easily break, so just order some before you get started.
• While in there, plan to put some Dynamat and Dynaliner on the firewall and on the inside of the dash to quiet things down.
• Blow everything out with compressed air, and do a deep clean before putting it back together, I used dishwashing liquid bath and a clean water rinse.



W460 Dash Removed Showing Heat Exchanger

• Use Deoxit on the electrical connectors.

The photo here is what it should look like after pulling everything out. That dust you see is over 30 years of dirt courtesy of the Austrian military. In the middle is the entire heating and blower unit. You will need to remove the side plenum ducts shown here prior to removing the center unit. There were three Phillips screws on each side. Don't attempt to remove the top plenum as it is difficult to remove and the unit comes out nicely with the top attached.

You can see the flexible side and windscreen ductwork has been removed on the right and the left it still connected. You will need to remove the top dash prior to getting the heater/blower out. There are two small Phillips-head screws in the back holding the top dash in place. Remember to remove the coolant hoses on the right side. Turn off the heat valve and have a small container handy as you will get some coolant spilling into your cabin.

Once out you will need to take the heat exchanger apart to get to the fan motor on the backside. This process is easier if you heat up the box a little with a hairdryer and use some trim tools to pry the tabs out while pulling the back off. Be careful the tabs are brittle and will break.

Once out you will see the fan and in my case the resistor for low-speed operation. My Puch-G only has two speeds later W460 trucks feature a three-speed fan. You can remove the cables by unplugging them from the motor, they are polarized so there is no way to plug them in wrong. Remember to spray the electric connectors with Deoxit.

Remove the two spring clips holding the motor and slip it out toward the back with the fan attached. The fan is very difficult to remove, but it is held in place with only friction, no glue, clips or screws. Be careful with the fan because you will notice some clips on the blades that were put in place to balance the fan; consider using some tape to hold them in place until after you get it installed again.

Clean everything very well. The new motor came with a plastic cover that made me think it would not fit, but the cover just needed to be removed. Also, on the back of my old motor is a small plastic cap covering the rear bearing, I carefully removed it from the old motor and snapped in on the new one. I slid the motor in place, installed the clips that held the motor secure, electrical connectors then finally mounted the fan. Once again the fan held in place on the spindle with friction and don't push it too far in as the fan will scrape against the housing. I tested the fan with a motor prior to putting the heater box back together.

I pulled out the heat exchanger (it looks like a radiator) and blew it with compressed air I also replaced the foam holding the exchanger in place as it was deteriorated. All the plastic pieces got a bath inside and out then I put the heater box back together.

Cleaned and Mounted Heat Exchanger

Then I simply reversed the take apart process carefully following the order; hint: leave the glove box, steering wheel, gauge cluster, and speaker cover for last - even after installing the center console. Here is how the cleaned heating unit looks installed before putting the dash back in. No more Austrian dust!

I also changed the heater valve cable. These are notorious for getting hard to adjust over time and with everything apart super easy to replace and adjust.

While all the parts were out, I took the opportunity to thoroughly clean the dash parts and put some Dynamat on the backside of the metal dash to kill that tin can sound. I also used some rubbing compound to clean up the painted pieces and polished them with car wax. All plastic pieces got a bath before putting them back in as well.

Some of the foam that was between pieces needed replacing so I used some adhesive weather stripping to replace the foam with new. Now the truck has a working fan that blows clean air and my dash looks good as new. Just remember - this project takes TIME. After 2 years of procrastination, my defective motor is finally replaced and the heater blows clean air.

Puch 300GD OM613A Turbo Swap

Anyone following the 2019 Barrett-Jackson auction in Scottsdale will quickly realize there is a strong market for well restored G-Wagons. With so much market potential, why not reimagine more G's? The first project for me was turning a G55 into an AMG G55 Squared. I know it was never a production model, but some portal axels, new springs, king shocks, bead lock wheels, and 35" tires... it comes awfully close.

What do to with a sluggish Puch 300GD? Last year I picked up a Getrag 5-Speed from Europe so why not the upgrade the OM617 naturally aspirated 3.0 diesel and 4-speed with an OM617A turbocharged engine with the 5-speed.

I've owned a turbo swapped 300GD before and you can really feel when the turbo kicks in. I'm looking forward to mating it with a 5-speed to increase the top end speed when driving on the highway.

For those not familiar with the OM617 of the '70s and '80s it was one of the most successful and bulletproof engines ever manufactured by Mercedes. Well maintained versions have been known to register over half a million miles without being rebuilt. At only 85 HP, the inline 5 powerplant was not zippy but they did feature good milage and when fitted to cars like the 300D they were well received in Europe and then later in the US. The engine featured a simple mechanical design that, once running, required no electricity.

In 1976 Mercedes started testing a redesigned engine that added turbo. Several records were set and over 200 HP produced was by test models. By 1978 production models existed and in the US it was mated to the W116 that became the first turbocharged diesel sedan. The 300SD became a popular car during the energy crisis ushering in the age of diesel power for passenger cars. As a turbo powerplant, the OM617A produced 121 PS (89 kW; 119 hp) @ 4350 rpm, torque 230 N⋅m (170 lb⋅ft) @ 2400 rpm.

Tuners have been known to squeeze more power from the 3.0 inline 5 OM617A by using high-performance fuel pumps, injectors, and turbochargers featuring intercoolers. Extreme cases have recorded  well over 200 HP to the crank although the longevity of the engine will surely take a hit.  

I've enlisted the help of the folks at Reinvent the Wheel to design the powerplant for my Puch G. They build a high-performance OM617A with an upgraded camshaft and Bosh M-style fuel injection pump to deliver an additional 40-50 HP over the stock OM617A. The plan is to exceed 150 horsepower when all is said and done.  

The upgrade will require the use of some components from the original engine, including the 24V alternator, power steering, glow plugs, flywheel and vacuum pump. I'll need a new clutch, for the 5-speed and a new shorter driveshaft. Once complete the truck should have better performance at altitude (I live at 7000' elevation) and at highway speeds. 

Look for a full review when the truck is finished in a couple of months. 

Once complete, the "turtle" will be going to the body shop for some touchup bodywork and I'll get started on bringing the interior back to its original spartan military specifications.

G55 Portal Update #2

I've been without my G55 since late May but I continue to get updates. It looks like all the parts are in and we have made the final decisions on the build. The folks at GwagonParts keep wanting to trick out the truck visually. Suggestions include newer G63 bumpers and ground effects, blackout all the chrome and even possibly a hood scoop. yea that would look awesome but I keep telling them FUNCTION over FORM.

To that end here is a final list of what we are doing:

Tibus 2nd Generation Portal Conversion that includes: 125mm Portals, 2 Front Steering Knuckles, Heavy-duty CV Joints, Heavy-duty Rear Axel Shells, Rear Brake Calipers, Rear Brake Rotors, Front and Rear Axle Braces and new ABS Sensors.

Suspension: G550 Springs, King 2.5" Performance Shocks with Extended Oil Reservoir - 20 Compression Settings, and Custom Reservoir on Shock.

Wheels: Tibus Aluminum Beadlock 18x9 Wheels in Matt Black, Nitto Ridge Grappler R/T 35x12 5R18 Tires,

Recovery: Thor Front Winch Mount for Mercedes G55, Smittybilt 97510 X 2O Waterproof Winch, Reverse Tire Mount for W463, Mercedes OMB 18' Wheel for Spare Tire, W463 Professional Roof Rack with Ladder and a Smittybilt 2781 5.65 CFM Universal Air Compressor.

This will replace my 2001 Jeep XJ that was sold on eBay: https://www.ebay.com/itm/183946968481 

G55 Portal Update

A few weeks ago I sent my G55 off to GwagenParts for a major upgrade. The goal is to untame the work done by AMG and turn the truck back into the off-road beast it was designed to be. And because I see all my cars as platforms to be modified, I decided the G55 should be reimagined as well.

While the entire suspension is getting converted to perform off-road, the main focus is providing lift and stability. That means portal axels rather than a traditional lift kit. Portals and new tires will lift the entire car, including the axels and differentials up an additional 7" while a traditional lift kit will only lift the frame and leave the axels and differentials to be banged up by the road.

I chose the Tibus kit offered by GwagenParts because of the excellent compatibility with the G55, relatively low cost, and quality German design/build. I also thought they would work well with the Tibus Beadlock wheels and King shocks.

So far the portals are installed with the softer and taller G550 springs and new KING shocks.

If all goes as expected, this will be a powerful 500+ HP, supercharged V8 beast of an off-road machine. I'll keep you updated on the progress as the build continues.

Saying Goodbye (for now)

I've been enjoying an AMG G55 as a daily driver for two years. In that time, I've taken it on road trips, some basic off-roading, and tooling around town in all sort of conditions. I've come to the conclusion that while it has a nice interior, it is and always be a truck.

I'm perfectly alright with that. A 500 HP truck with a supercharged V8 is really what this Georgia boy wants to drive around. I even like the nice entertainment system (stay tuned), the climate-controlled leather seats, and all the fancy Mercedes features. The thing is when AMG supped it up, they took some of the truck away and tried to make it more street friendly.

I've decided to go big and make it much more like a truck. Today I'm saying goodbye to my truck because it is going away for a makeover at G-Wagon Parts. I'm going to get a trailer hitch, portal axels, off-road springs, KING shocks, bead lock wheels and proper truck tires. More to come!

Through the Roof!

Barrett Jackson featured three G's and all went for crazy money. Are people finally starting to see the real value in these iconic trucks? I previewed the offerings a few weeks back and featured one stand out example but did not take a deep dive into the other two.

For perspective, you can usually find a clean 80's model G for under $20,000 and a late model AMG version for about $70,000 but what I saw at auction was a bit shocking. Join me for a quick summary and final auction results for all three. 

Let's begin with a wonderfully restored and presented 1987 Wolf. I spoke with the seller and profiled the truck in this blog post just prior to the sale. It seems this car was restored by a professional group out of Germany and I can tell you the attention to detail was exceptional. 

I was pleasantly surprised to see this truck bring $60,500 at auction. Based on these results, expect to see me document the restoration of my Puch-G cabriolet.

Sold on the final day was called a 1996 SWB Europa. I took a good look at this truck and was not impressed. The interior looked worn, the paint job was spotty at best and when I looked under the hood liner, there was a lot of surface rust. Whoever did the bodywork did a poor job and lacked attention to detail.

I was interested so I took the VIN and did some searching and found a forum post that included an entry by someone claiming to be the previous owner. He said the car was purchased from Mastodon for around 25K with a rebuilt engine (300 block and 350 head). I also found the truck offered by CNC Motors for $59K.

I did not attend the final day but was shocked to see this car went for $41,800 at auction. Lesson: Do your research before bidding. 

Finally, let's go crazy. The AMG Mercedes G63 6x6 is a rare bird indeed. It is thought that about 100 were made between 2014 and 2015 and as with any low mile limited edition car they tend to bring a LOT at auction. To illustrate the high expectations this was one of the few lots offered with a reserve. 

The only thing that kept me from purchasing this car was the color. Everyone knows that only the UN should be allowed to have white G-Wagons. 

Even without me bidding, the 2014 example with less than 1000 miles at Barrett-Jackson 2019 broke the one million dollar mark by going for $1,210,000! The crazy thing is, these are titled with a special show title in the US limiting them to only 2500 miles per year. Can you imagine purchasing a truck for over a million and turning it into a trailer queen?

I'm convinced now more than ever those of us with well maintained G's in the states should invest in making them right and auctioning them off!

Brush Guard Quick Release - FOUND

When I got my G55 the brush guard was loose. Turns out one of the quick release bolts was missing. When I called the Salt Lake MB dealer where I purchased the truck about the missing part they quickly offered to find me one. Two weeks later I got a call saying that Mercedes-Benz parts did not have any and they could not find one. A year later I was in Pheonix and it was time for my "C-Service" so while at the service desk for Glendale Mercedes I asked again if they could find the quick release bolt. They said no problem and, like before, after two weeks of looking they could not find one.

I then turned my attention online and checked Four By Four Club and Euro Truck Importers and both showed the part out of stock just as the previous year. This is so strange because the bolt is a common part used by the OEM brush guard for years. 

For those of you who have removed your brush guard, you know this is no normal bolt. It uses a special tool and is not something that can easily be replaced. 

Last week, I decided to look hard to locate one. I looked on eBay, checked the usual places again and after coming up short, started looking on Google images. After some digging, I finally found one. Yes, the price was high, but I was approaching desperation. I had never ordered anything from G-Wagon Accessories before but now it was time to change that so I ordered it. The bolt came in three days and fit perfectly. 

While there I looked over their offerings, and while the prices are high, they do offer a lot of accessories that can enhance the off-road experience of late model G-Wagons. I may have to get the rear bumper and trailer hitch!

Very Special Opportunity

Back at the 2019 Barrett Jackson Auction at Scottsdale where I was able to dive into the three G-Wagons offered, get hands-on looks at each and in one case, speak to the seller. Let's begin with a surprise stand out. The orange 1987 240GD that is offered at no reserve on Friday's auction is an excellent example.

I met with Jeremy Sandler of Segal Motorcar Company who has several cars up for auction and he let me crawl all over the 240GD. This example appears to have started out as a W461 German Military Radio Wolf truck. As you would expect, it has a 24V electrical system with battery shutoff below the center dash. Like the Austrian Puch, the naturally aspirated 4-cylinder diesel engine has features that will allow the truck to operate in about 3 feet of water.

Jeremy told me the truck had been restored in Germany at some point then brought back to Canada. Whoever did the restoration did a wonderful job. The orange paint maintains the flat finish of the original military green and has been expertly applied. I found none of the usual signs of rust on any of the body panels. The suspension looks to have been removed and some parts powder coated and springs and shocks were both upgraded. With such a thorough restoration, I was a bit surprised the original metal fuel tank was not replaced with the upgraded plastic unit found in most modern G-Wagons because there are signs of patching. The rear skid plate that covers the fuel tank is also missing. The trim surrounding the upgraded headlights is ABS and not the original rubber type but look like new as does the rest of the exterior trim. The grill also looks to have been replaced with a newer unit but still maintains the original look.

The interior is a very nice upgrade while maintaining the truck's military bones. I like the way the orange theme was carried into the interior with piping and stitching. The front seats are comfortable and look great, all gauges look clean, all controls are in place and the rear jump seats are restored to a like-new condition. Looking under the mats there was no sign of repair or rust. I appreciated the decision to resist upholstery and use ABS panels on the doors to maintain the spartan feel of the truck. Also nice was to see proper size tires and original wheels. There are enough 80's G-Wagons with oversized wheels and tires and they actually perform better with the right size.

The engine compartment is very clean. Once again orange accents are found under the hood but only on hoses. The only visible upgrade was the new aluminum radiator. The padding under the hood is missing, but it was reinforced to support carrying loads on the hood using the straps. Underneath I found no evidence of fluids seeping from any of the differentials, transfer case, transmission or engine. I'm not familiar with the 240 but was surprised to see there was not a fuel return hose coming from the last injector to the fuel tank as is present with the 300. The rear hose was simply capped off.

It was a pleasure to encounter a well restored and preserved W461. While not strictly restored, this updated model reflects the military heritage of the original with a new theme. For anyone looking for a truck to run around an island, orchard, vineyard, or private ranch this would be a perfect way to get around with a nice level of style. And while I prefer collectors to drive their cars, this one would be right at home tucked away in a collection to be driven only once in a while.

After all was said and done this example brought $60,000 at auction. 

G's at Barrett Jackson Scottsdale

There is no limit to the hype surrounding what many auto enthusiasts believe to be the most anticipated auto auction. This week, we will experience the Barrett Jackson Scottsdale 2019 auction behind the scenes with first-hand interviews with owners and bidders.

This seems to be the year of the truck with a lot of activity around the Dodge Power Wagon and Broncos but because our focus is G-Wagons we will follow three particular auctions. The first to come to auction will be lot #987 1987 240GD Cabriolet then lot #1410  2014 G63 6x6 and finally  #1575.1 1996 Europa G. Lets take a quick look at each one. 

240GD Cabriolet

SWB G-Wagons are very popular, add the indestructible diesel engine and removable tops are a huge draw. The color combination on this G is very nice. While underpowered and not a great highway driver, this is a wonderful off-road truck and would be a great weekend driver. The builder did a very nice job with the interior. It will be interesting to see what this car brings at auction on Friday.

2014 G63 6x6

Barrett Jackson feels like this will end up fetching the big dollars because it is being auctioned on Saturday and one of the very few with a reserve. With only 607 indicated miles on this limited production truck I can understand why! Featuring 6 portal axels, 18" beadlock wheels, bi-turbo AMG 536 HP engine, impressive stance, and clearance that a 9-year-old child can walk under it is menacing. Featured prominently in the main tent, everyone that walks past this example stops, points, and shoots a photo. #crazymbpickup

1996 Europa G

This is my personal favorite. Almost impossible to get in the states, this no-frills G is a great daily driver and off-road warrior. Unlike our first two examples, this SWB has what I feel is the just the right amount of power. Not too much like the G63 and not too little like the 240G it is just right. Add tasteful interior that anyone would find comfortable without the US Spec frills and this is one of the great items that will close the week on Sunday. 

Stay tuned as we visit the floor, talk to the owners and follow the bidding on this weekend to see how healthy the market for the G's are in 2019. And while we are here, we will take a look at two other trends in the 4x4 market Broncos and Dodge Power Wagons. Stay tuned!