Any sage advice on R230 roof actuator flap mechanism?

[DeanoPremo]

Has anyone had the experience of the central drive cog that works the two boot mounted roof flaps stripping most of it's teeth?

Only the cog is faulty so I need to find someone that can machine or laser a 2cm long cog with a square central shaft....

It's either that, or I need to buy the whole flap mechanism with motor, cables etc. Used part only possible as long back order quoted by MB.

Any input appreciated!

 

[ajlsl600]

Maybe someone with a decent 3d printer?

 

[Uncle Benz]

I have repaired the flat rack cog part before by careful welding to build material up on the stripped teeth and filing them to shape. Fiddly, but take your time and it actually works!
They’ve been on back order for years. That’s why I gave up and had a go at repairing.

 

[peterws1957]

It might be worth trying HPC Gears in Chesterfield. They sell all sorts of really obscure gears and I've had several from them where a manufacturer has told me that their part is no longer available. Not cheap but probably cheaper than replacing a complete unit. I've sent gears to them in the past and they'll match it for you or make a replica.

 

[DeanoPremo]

Maybe someone with a decent 3d printer?

My first thought, thanks but nobody thinks the 3d materials would take the hammer...

 

[DeanoPremo]

I have repaired the flat rack cog part before by careful welding to build material up on the stripped teeth and filing them to shape. Fiddly, but take your time and it actually works!
They’ve been on back order for years. That’s why I gave up and had a go at repairing.

This is beyond my skillset but I am suggesting today that if a band of weld metal is built up enough, a gear cutter could be applied. Thanks!

 

[DeanoPremo]

It might be worth trying HPC Gears in Chesterfield. They sell all sorts of really obscure gears and I've had several from them where a manufacturer has told me that their part is no longer available. Not cheap but probably cheaper than replacing a complete unit. I've sent gears to them in the past and they'll match it for you or make a replica.

Many thanks, I am in South Yorkshire so they are on my hit list for today........

 

[SL63 Mark]

Has anyone had the experience of the central drive cog that works the two boot mounted roof flaps stripping most of it's teeth?

Only the cog is faulty so I need to find someone that can machine or laser a 2cm long cog with a square central shaft....

It's either that, or I need to buy the whole flap mechanism with motor, cables etc. Used part only possible as long back order quoted by MB.

Any input appreciated!

Take it to a local machine shop, you'll be surprised what they can do. Be prepared to pay though. Some won't touch small fiddly jobs like this, but if you strike up a good relationship with one (and are generous with the cheque book) you'll be amazed what they can do. Some like the challenge of one-off small jobs, it gives them a break from the mind numbing production work.

Same thing happened to my 2004 SL55, it is a common fault on the R230. Back in those days, MB still had replacement parts, so I replaced both sides.

Easy DIY. Sad to hear parts are no longer available.

 

[DeanoPremo]

Take it to a local machine shop, you'll be surprised what they can do. Be prepared to pay though. Some won't touch small fiddly jobs like this, but if you strike up a good relationship with one (and are generous with the cheque book) you'll be amazed what they can do. Some like the challenge of one-off small jobs, it gives them a break from the mind numbing production work.

Same thing happened to my 2004 SL55, it is a common fault on the R230. Back in those days, MB still had replacement parts, so I replaced both sides.

Easy DIY. Sad to hear parts are no longer available.

Spot on, went to a couple yesterday that just couldn't be arsed, persevering today. Got to try and bring it in for under £3-£400 as you can buy the entire mechanism for that.

 

[Craiglxviii]

Spot on, went to a couple yesterday that just couldn't be arsed, persevering today. Got to try and bring it in for under £3-£400 as you can buy the entire mechanism for that.

That’s only if you can get the entire mechanism!

 

[DeanoPremo]

That’s only if you can get the entire mechanism!

Roger copy that.

 

[ajlsl600]

Hmm? R230 parts starting to become u avail. That wud be a shame benz have not, in recent history made a more likely classic

 

[DeanoPremo]

I have repaired the flat rack cog part before by careful welding to build material up on the stripped teeth and filing them to shape. Fiddly, but take your time and it actually works!
They’ve been on back order for years. That’s why I gave up and had a go at repairing.

Hi Uncle Benz, I have got interest from someone but they have concerns that the part will take a weld. I have nothing to come back with as I don't even know what the alloy is composed of, just that it is magnetic. Can I enquire into what you used Sir?

 

[Uncle Benz]

The rack part with the teeth on it is steel. I welded to it with my Mig no problem.

 

[DeanoPremo]

The rack part with the teeth on it is steel. I welded to it with my Mig no problem.

Much appreciated. I have managed to find a young apprentice with a BNFL rated engineering company (Son of a friend) who thinks it will make a nice project so I will tell him how you handled it....

 

[Uncle Benz]

Much appreciated. I have managed to find a young apprentice with a BNFL rated engineering company (Son of a friend) who thinks it will make a nice project so I will tell him how you handled it....

It’s a very simple rack and pinion that carries hardly any load on it. It doesn’t have to be absolutely perfect to work, but get some grease on it when it’s repaired. They are practically dry from the factory which doesn’t help.

 

[DeanoPremo]

It’s a very simple rack and pinion that carries hardly any load on it. It doesn’t have to be absolutely perfect to work, but get some grease on it when it’s repaired. They are practically dry from the factory which doesn’t help.

Thanks muchly, that's reassuring, I did wonder how much hammer it took to shear all but one of the teeth off. I also noticed that apart from a dried out token remnant that there was no noticeable lubrication so your advice is very much noted. The young man who has taken on the repair is going to laser cut in sections then weld them together.....gulp

 

[00slk]

Hmm? R230 parts starting to become u avail. That wud be a shame benz have not, in recent history made a more likely classic

Not only R230 parts, but S211 bits too ajl