Mercedes G W463 complete rebuild (44 chapters)
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- เผยแพร่เมื่อ 22 พ.ค. 2024
- This video is created from 1039 photos organised in 44 chapters. Each chapter presents separate step in my Mercedes G W463 1991 complete rebuild process. I am personaly not a biggest fan of video composed of photos but when I was starting this project I did not concider to share it. No voice over or music. Anyway I picked distinct photos so if you are interested in some particular subject here you have it:
00:00 SEPARATING BODY AND FRAME
03:03 DISASSEMBLING FRAME
03:48 REBUILDING FRAME
07:00 ENGINE SPECIAL PARTS
08:03 OM606 ENGINE
12:36 BMW GS6-37DZ GEARBOX
14:33 STICK SHIFTERS
14:54 ENGINE AND GEARBOX ASSEMBLED
15:06 EXHAUST
16:18 ADDITIONAL FUEL TANK
17:27 FRONT BUMPER
18:12 REAR BUMPER
19:36 FRONT SKID PLATE
20:12 REAR SKID PLATE
20:18 TRANSFERCASE SKID PLATE
21:03 WINCH
21:33 SNORKEL
21:51 TRANSFERCASE
22:21 DRIVESHAFTS
22:45 DRIVESHAFTS TOP COVERS
23:06 FRONT AXLE
25:06 REAR AXLE
27:57 FRAME ASSEMBLY
30:21 BODY DISASSEMBLY
32:48 BODY BEFORE REBUILD
34:09 BODY REBUILD
37:33 BODY AT PAINTSHOP
40:42 ENGINE BAY SIDE WALLS
41:06 SLIDING ROOF
41:57 OUTSIDE MIRRORS
42:30 CLUTCH AND BRAKE PEDAL BOX
42:54 STEERING COLUMN
43:06 FRAME AND BODY ASSEMBLY
44:12 FRONT RADIATORS
45:33 MERCEDES LOGO
45:45 SEATS
45:57 INTERIOR ASSEMBLY
47:03 DASHBOARD
48:03 ROOF RACK
49:12 SNORKEL AND AIR FILTER
50:15 REAR REGISTRATION PLATE HOLDER
50:21 ROOF RACK CABLE MOUNT
50:36 DASHBOARD BETWEEN SEATS
51:27 G READY FOR OVERLANDING - ยานยนต์และพาหนะ
WTF! nicest w463 restoration ever!!!! nice build, much more quality than factory build
Thank you for the comment, very much appreciated.
Oh my god! Sir, I salute you! Can’t imagine how much money, how much time and effort you had spent on this car. Congratulations.
this video is a lesson for us that we want to to rebuild a g class!thank you so mutch!
Fantastic story 🙂. I am in the process myself and are still taking everything apart on a GD 300 SWB. This is a inspiration! Thank for sharing!
Good luck with your rebuild!
Thanks for sharing all of your hard work. I just bought a 1991 300GE. There is so much to do.
This is the best G class project I have ever seen! Big congratulations to you, it is very impressive what you have done. I hope I can do the same one day. Greetings from Belgium!
Thanks, much appreciated!
This cars is a life
The workmanship is great, super tidy work….
I am doing the same thing since a few years, not as nice as yours but i love it. Would be interested in that fuel tank as well. Not able to get to the TH-cam contact page…
nice.i need like this reems
Beautiful
impresionante trabajo, felicitaciones
Thank you so much this video is very helpful! I’d love the cad file for the fuel Tank to go on my SWB
You can send me your email through youtube contact page and I will send you dxf files.
przepiękne auto
You have built the best w463 on the planet, thank you fo sharing! Do you have a dropbox will all these photos?
Sorry, no
@@MercedesOffRoadClubif not you then who?
Cool build👌, what car did the roof rack come from?
Thanks! This is standard ARB (220cm if Im not wrong) roof rack that I bought many years ago. I extended it to 250cm now, they are not specific to any kind of vehicle.
Hi, great work! I am in the process of gettin my W463 engine swap started and I would like to now what model version was yours originally and if the swap was not so hard to do? Any special recommendations based on your experience? Your feedback is much appreciated. Thank you
Thanks. My G is 463.328 from 1991, long wheel base, 300D (OM603.931 6 cyl inline 113HP, non turbo) 5 speed manual gearbox (5th is 0,800 ratio) 1,05/2,16 ratio in transfercase and 5,28 in axles.
Here you have two my videos about engine swap:
th-cam.com/video/xz78KT_gaU8/w-d-xo.html
th-cam.com/video/Y6GDcmdddYQ/w-d-xo.html
And complete playlist:
th-cam.com/video/_zyU6jQbDMw/w-d-xo.html
For me it was more time consuming than hard to do. Good luck.
Great work. Really you do a awesome work. I can only dream of something like this : )
OM606 is a great engine whit a huge potential.
One question only, why bmw gearbox ?
Its complicated ;) It is my first swap and rebuild so some mistakes must have been done. Basicly on decision date (before I started this rebuild) I wanted to have much better gear shifting mechanism than factory and stronger gearbox as well. In order to get that you need 3 most important things: reliable connection with engine (clutch etc), proper gear shifting mechanism and right output flange to transfer case - rest is easy like gearbox mounts to frame. At that time I found products from dpuk as complete solution, but now I would rather do it with Merc box and dual mass fly wheel, which I had in factory. With dual mass fly wheel its more soft. Generally it does not have to be final version, there is usually room for improvement ;)
@@MercedesOffRoadClub why didn't you install a 722.6 NAG1 automatic transmission?
This car came out from factory as manual in 1991 and I wanted to keep it like this, I have also got used to it. Another thing is that I wanted to keep it mechanial and no electronics, with 722.6 I would have to go with some TCU. Basicly I like this swap to BMW box but there is an issue with single mass fly wheel - its too stiff. In off-roading vehicle this connection should be softer.
@@MercedesOffRoadClub Mine is a G300GE built in 06/1990 with a manual 5-speed gearbox. I also have the 6-speed 717.654 and the 722.645 from the G55 separately. The OM606 is currently being revised, if I decide on the automatic transmission it will only work with OfGear. I often go to Upper Silesia Swibie near Toszek because my car was overhauled there and I was born there.
Ok, thats not far :)
Hello, first of all, best wishes and my respect for the project. Can you tell me why you decided in favour of the BMW gearbox? What exactly is the advantage of the BMW gearbox compared to a Mercedes gearbox?
Thank you for the comment and sure I can. I already had few questions about this gearbox. Its little hard for me to explain for your best understanding, but I will try. So I allways wanted to make this rebuild and I had my plan. This was my first swap and rebuild, I did not like my factory gearbox in G and shifting mechanism, so I was little discouraged to Merc boxes, I knew that I would have to do many things in this rebuild, I wanted to have solid solution (engine to gearbox connection). I wanted to have super shifting mechanism. By buying kit to connect this bmw gearbox "all" I had to do was at the back of it and at decision day (exactly 4 years ago) this seemed to be reasonable.
Current status: After 4000km that I drove in summer 2023 I know that I like this gearbox a lot, it has very nice shifting mechanism, it is very solid and I just love shifting its gears and all work around it is pretty clean. There is only one thing that is wrong: single mass flywheel - this is a small bummer. The connection between engine and all further drivetrain for offroading with single mass fly is to hard. Single mass is solid and reliable but more for street or race.
For this year (2024) I plan to finnish my overlanding conversion and finally go for some trip.
In winter 24/25 I plan to review my gearbox and at first I will try to find some solution with dual mass fly wheel for this bmw gearbox, if this is going to be impossible I will probably switch to Merc 370 6 speed gearbox, but this is not decided yet. I put a lot of effort to swap this bmw gearbox.
If I started again from scratch overlanding G I would go with dual mass fly and Merc 370 6 speed gearbox.
Best wishes for You as well!
Cheers!
@@MercedesOffRoadClub Hi, thanks for the explanation. I drive a 290 GDT and a 270 CDI. Both are W461 and I also sometimes consider converting to OM606. A colleague of mine also has a 290GDT and has converted to a manual gearbox. I am also in the Mercedes G Club DE. I've seen the mug.
Both great Gelandewagens! Swaping to OM606 is great garage adventure. I stayed with manual gearbox becouse my very early W463 (1991) had manual gearbox from factory.
Amazing build, but may I ask why? I bet this cost a lot of time and even more money. Why not just get a clean low mileage 2002 G500 for a fraction of the price?
Sure, I always try to reply, there are many reasons:
I always wanted to rebuild this G from scratch - I had my plan +/-
I wanted to build my own overlanding G - I like overlanding and spending my spare time (holidays) more in nature/exploring and seting my own wild bivuac
I like to weld and faricate
Im more diesel guy than gas, so OM606 fits my style
G500 is more luxury inside and I like "W124" or W461 style inside
Older Gs have simplier electrical installation
Fuel cosumption with G500 on 35 inch tires would be propably twice as much (my guess)
Ok, starting this project with G with better condition would be little faster/simplier/cheaper, but I could not abandon my friend, we traveled pretty a lot togehter
Propotion of time and money you sugest is rather opposite - I would say I spent more time than money.
It was great garage adventure and experince
I have learnt a lot
Driving this G now is pretty much big satisfaction
And I have grown (a little) my youtube channel
There are propably some more other reasons, but I have to go garage and fix some oil issues in my OM606 ;)
@@MercedesOffRoadClub Fair enough reasons, I bet these types of restoration projects are meant more as a hobby than as an investment and it makes more sense to do these yourself vs taking it to a mechanic. The 2002 NA Spec G500's are more mechanic-friendly and more for the average person. I personally love more luxury and power so I went with the G55K. Major respect to you for bringing this Old G back to life.