Converting 500E to ME 1.0 and NAG1 5-Speed 722.6

[ijibon]

Sorry, this one is out of the topic.
Billet PA6GF30 PWM fan shroud for 500E.
Of course, this was made from 3D scanning OEM radiator, W204 fan shroud and redesigned as a hybrid.
You can delete mechanical fan, two electric additional fans and the annoying resister.
Bolts on OEM radiator and W204 PWM fan fits right on.

We are trying to make a kit with controller (standalone) and wiring now.
If you are interested, please let me know.
The number gets bigger, the cost gets cheaper.

Dear Sir,
Is the electric fan, elimination of the clutch fan, available for sale?
Thank yuo for taking time to reply.

 

[gsxr]

@virage, will the 3D-printed hybrid fan shroud be for sale separately? What part number 204 fan is required? There are several different 204 fans, I assume not all will fit the hybrid shroud.

 

[virage]

Dear Sir,
Is the electric fan, elimination of the clutch fan, available for sale?
Thank yuo for taking time to reply.

Hello ijibon,

Yes it is.
But it is made to order.

 

[virage]

@virage, will the 3D-printed hybrid fan shroud be for sale separately? What part number 204 fan is required? There are several different 204 fans, I assume not all will fit the hybrid shroud.

That is correct.
Actually, the shroud is not 3d printed though.
It is machined from a big brick of PA6GF30.
I will get back to you with part numbers and pictures of the motor unit.

 

[virage]

Here is an example.
But the blade and the motor units are not sold separately.
So you have to purchase the whole unit.
But you can find motor and fan only in ebay.
Maybe some other units that are not for W204 have the same motor and the blade.
Just choose the one with the same motor and the blade.

 

[virage]

The price is 1850 usd excluding the motor and the blade.

 

[500AMM]

That is correct.
Actually, the shroud is not 3d printed though.
It is machined from a big brick of PA6GF30.
I will get back to you with part numbers and pictures of the motor unit.

In case someone wonders what PA6GF30 is - Polyamide reinforced with 30% glass fiber:

PA6 GF30 - PA6 30% glass fiber: Key features & uses

What is PA6 GF30? Are there any other types of glass-filled PA6 compound? Let’s discover the key features, benefits and uses of this popular material.

europlas.com.vn

It is a perfect material for such an application as the fan shroud.

 

[Markus-MD]

Maybe the only one.This is very stable at high Temps also at low temps. When you printed this with ABS over other Plastic your Temp Range is aprox 90-100 degres .at this point fading to soft struktur..Printing is in my mind no Option.Only cuting from one Block. And the Maschine has work 3-4 or 5-6 hours to work.I dont know exaktly.,Also 1850Usd ist not less but i found is a good price for a long term of Development.Respekt to Virage and Niibe

 

[virage]

Maybe the only one.This is very stable at high Temps also at low temps. When you printed this with ABS over other Plastic your Temp Range is aprox 90-100 degres .at this point fading to soft struktur..Printing is in my mind no Option.Only cuting from one Block. And the Maschine has work 3-4 or 5-6 hours to work.I dont know exaktly.,Also 1850Usd ist not less but i found is a good price for a long term of Development.Respekt to Virage and Niibe

Thank you Markus.
You are absolutely right.
We made the shroud with 3D printing first, which costs almost the same, did not hold with the temp.

This shroud fits right on to the original radiator, I mean right on.
There are many after market products that are advertised right on or bolts on,
and they never did.
And I wanted it look as normal.
You see all those DIY level after market parts that look ugly and they are for little brats saying "Look at me".

Also, I am not making much profit.
I just did it for my customer who can pay for it.

The one I have sold is on a 500E that is being used daily near Tokyo.
Through traffic in last summer and had no issue.

 

[Jlaa]

Sorry, this one is out of the topic.
Billet PA6GF30 PWM fan shroud for 500E.
Of course, this was made from 3D scanning OEM radiator, W204 fan shroud and redesigned as a hybrid.
You can delete mechanical fan, two electric additional fans and the annoying resister.
Bolts on OEM radiator and W204 PWM fan fits right on.

We are trying to make a kit with controller (standalone) and wiring now.
If you are interested, please let me know.
The number gets bigger, the cost gets cheaper.

I am interested. I will private message you now. Thank you.

 

[Jlaa]

An update to readers of this thread -

@virage has developed a beautiful product - a fan shroud that looks completely OE, made of OE materials. It is made to accept the w204/w212 E500 electric fan and fit the fan into a w124.036 car, replacing the mechanical fan and unlinking fan speed from engine speed. The benefits is better cooling air management at low driving speeds and potentially quieter operation.

The shroud is a two piece design milled from a single block of material. It is beautiful, but, unfortunately, I am not able to afford the price of this shroud as it stands for a production run of 1pc as it is made to order.

If this interests any one else here, perhaps we can get together and approach @virage and see what pricing might be like for multiple pieces. Thanks.

 

[Otrebla49]

No affiliation with the company on the YT-link
========

That being clarified - let's try add some scope of possibilities to Jan's (@124500E) original inquiry here - so that others among members of the Board may look at one example of conversion (although I am not sure about ME-1.0 taking place).

I was doubting whether opening an exclusive thread for content bellow, but then found this one created by Markus who had similar goals.

Title of such thread would have been:

" 'SG50' W124036 - BUT! - €50k improvements static-ignition and 722.6 tranny / 6-caliper front brakes and carbon-ceramic discs from AMG - PWM command for auxiliary cooling fan!! "

YT-link (sorry audio only available in German) into this 'SG-50'-project - not a cheap one, estimated €50k spent by customer - shows results and presents performance after 722.6-swap, and distributor-less ignition usage was done.

Raphael, who runs Stern Garage, also says on YT that he implemented a PWM-solution for cooling auxiliary fan too - which starts supplying aprox. 40% duty cycle at 88° C, leading to gauge needle practically never rising above the 90° C mark on the cluster.

He continues to tell how events developed - customer brought his 500E to Stern Garage (in mid-Northern Germany) with broken chain guides - at 190k km (116k miles) - and opened his check-book. His unique requirement was that all modifications were accepted by TÜV officials - latest achieved with an emissions evaluation cycle as to register the exhaust piping and mufflers with new SPORT-cats included!

I randomly ran into this precise 124036's owner in summer 2024 at 'Cars & Coffee' in Sindelfingen - on a sunny afternoon during an official gathering, close to the manufacturing plants of Mercedes-Benz - and he briefly explained to me the works that had been done to his car (as I spotted different brakes and gear selector than standard on it) - pointing at me to search for 'Stern Garage - 50,000 € conversion project' on YT for detailed infos (and extended joy too!)



Ps. And spoiler - that car is the one pictured on my profile photo from today on - but I unfortunately do NOT OWN any e500e and attended the gathering as a pedestrian - same as my visits to MB-museum in Stuttgart during this year!

More pics from the event are attached..

Have fun while watching it!
Alberto