Author Topic: Heater Lever Frame Replacement (Read 7571 times)

getsmart · « **on:** January 02, 2020, 05:22:48 »

Hi all,

Does anyone know if the heater lever main frame is a replaceable part? I've not been able to find a part number for this. Mine has completely fallen apart. I'm curious what this was made of as it appears to be almost a cross between bakelite/plastic/alloy of some sort !!!

Mine is from a 1964 230sl.

1st photo is an example of an intact frame and 2nd photo is mine.

Rgds, Joe

The Red Car

ja17 · « **Reply #1 on:** January 02, 2020, 06:13:33 »

It is a zinc casting (metal). It is unusual that this needs replacement. I think the whole assembly with the levers is still available from Mercedes. It was around $600.00 list at the dealer last time I checked.

getsmart · « **Reply #2 on:** January 02, 2020, 07:07:43 »

Thanks Joe, yes I don't know how it ended up in such bad condition but its cracked,warped and very brittle - and in 2 pieces (I bought the car as an unfinished project). At $600 USD I'll be fabricating a new one myself - perhaps out of acylic -seems to be strong enough - only problem is mine is in such bad condition that I'd need a good one as an example to get the correct dimensions, especially the dash anchors. Or some accurate engineering diagrams.

getsmart · « **Reply #3 on:** January 02, 2020, 09:31:02 »

If someone had a few good images of one I may be able to fabricate a new one - the image below is the best I've been able to find so far. Dash mounting point measurements centre to centre would help tremendously.

EeVeeWee · « **Reply #4 on:** January 02, 2020, 10:22:52 »

This one is from a 230SL 1965.

ja17 · « **Reply #5 on:** January 02, 2020, 17:00:46 »

I think I would try to find a good used one or modify as sedan unit which is similar in many ways.

114015 · « **Reply #6 on:** January 02, 2020, 18:30:02 »

Hello Joe (getsmart),

Fully support what Joe (JA17) mentioned...,
try to find a decent used one.

Making/fabricating/3D-printing one is too much hazzle.

There are/were soo many 230ie parted out in the past,
go and try e.g. Euro7 (ebay) or similar,
at least the first gentleman surely has got numerous ones.

Good luck,

A.

getsmart · « **Reply #7 on:** January 03, 2020, 11:03:41 »

Thanks Joe/Achim/PWV for your replies. Are you referring to w108/w109 when you mention to use 230e part?

Attached are the w108/109 equivalent. Would you know if they are the right size? Remember I'm talking about the frame, not the control levers.

Rgds, Joe

getsmart · « **Reply #8 on:** March 18, 2020, 10:31:19 »

Hi all,

Call me stupid or maybe I'm just too tight with money but I couldn't part with the amount of money to buy a used frame so I hatched a plan to fabricate my own out of aluminium.

I had to glue the original frame together (which was in multiple pieces) just so I could take the required measurements to be able to accurately fabricate the new one.

The pics tell the story

Jonny B · « **Reply #9 on:** March 18, 2020, 15:09:16 »

Most impressive, how did the install of the new piece go?

jeffc280sl · « **Reply #10 on:** March 18, 2020, 22:25:36 »

Respect, nice skills

getsmart · « **Reply #11 on:** March 19, 2020, 02:28:54 »

Thanks guys,

Yes Jonny all works as it should. And all you need is a router, bandsaw and circular saw. Luckily aluminium is soft and actually does less damage to a wood blade or router bit than most types of wood.

I had to make a template to route the holes and tap and die set for the little M3 and M4 screws.

getsmart · « **Reply #12 on:** March 19, 2020, 02:47:23 »

I also replaced the original BA7 globes with BA7 leds, bit bright maybe

getsmart · « **Reply #13 on:** March 22, 2020, 10:01:31 »

I will keep these templates just in case someone one day has to reproduce the frame - they are made to suit 3mm Angle aluminium. I used 100mm x 50mm angle at 3mm thickness.

Rgds, Joe

col320ce · « **Reply #14 on:** March 22, 2020, 12:01:05 »

nice work!
I'm pretty sure there is some felt (or something) that stops the light bleeding around the levers. Make sure you pop that in before installing.

getsmart · « **Reply #15 on:** March 22, 2020, 12:12:17 »

That might explain the grooves that are in the original frame right at the very front of the frame both top and underside!!! Thanks Col!

mrfatboy · « **Reply #16 on:** March 22, 2020, 16:21:06 »

Do you have any more pictures of your manufacturing process?

You should upload pictures and the templates to the tech manual.

PM me and I can help if you are unsure how to do it.

Pawel66 · « **Reply #17 on:** March 22, 2020, 20:39:02 »

I think this is a fantastic work and brilliantly documented. Lots of us can benefit from it.

getsmart · « **Reply #18 on:** March 31, 2020, 08:16:53 »

Thankyou Pawell

Unfortunately MrFB I didn't take photos of the manfacturing process. Its extremely detailed and most people would probably just purchase a replacement - its just that I'm such a tight arse!!! And maybe I like a challenge too

cfm65@me.com · « **Reply #19 on:** November 10, 2020, 16:53:54 »

Hey Mr Getsmart,
Don’t be modest. You ARE smart, very smart.
Many, many years ago, I used and modified a 108 setup for my 230SL, which I had at the time.
It was a hell-of a job and if I remember correctly, I only replaced the plastic discs.
WELL DONE and please keep the templates.
Regards
Chris
Cape Town

jim 56 · « **Reply #20 on:** November 11, 2020, 17:57:24 »

That looks great sure it was a lot of work.

Chris Long · « **Reply #21 on:** November 11, 2020, 20:08:05 »

If there is demand and a pattern I do have a friend with a local (1 person) CNC machining business in either aluminum or plastic...

doitwright · « **Reply #22 on:** November 12, 2020, 01:46:52 »

CNC would be the way to go if producing several copies but having an original part would be a preferable starting point.

getsmart · « **Reply #23 on:** November 12, 2020, 05:39:25 »

Thanks Chris and others,

It did take some engineering with a limited tool set and no way can I let myself throw out the templates with the possibility of someone needing them some day.

Best regards,

Joe

Quote from: cfm65@me.com on November 10, 2020, 16:53:54

Hey Mr Getsmart,
Don’t be modest. You ARE smart, very smart.
Many, many years ago, I used and modified a 108 setup for my 230SL, which I had at the time.
It was a hell-of a job and if I remember correctly, I only replaced the plastic discs.
WELL DONE and please keep the templates.
Regards
Chris
Cape Town

getsmart · « **Reply #24 on:** December 25, 2021, 09:45:44 »

Today I finally tried a mock fitment into the dash and by a stroke of luck she fits!!!!

News:

Author Topic: Heater Lever Frame Replacement (Read 7571 times)

jeffc280sl