Bikeman71's 2004 G-Wagen Build

Bikeman71

Observer
I've learned so much from this forum that have helped with several builds over the years that I feel it's time I contribute by sharing my experiences on a new-to-me 2004 Mercedes G500.


I've been on the search for a G-Wagen for quite some time. I've studied and traveled a lot to do my best to find the perfect rig. My suggestion to those who are on the hunt for a G...drive as many as you can, regardless of your intent to buy. I drove a G55, a G550, and G500 during our family vacation to the Northwest. I knew that two of the three were out of my price range, but driving them gave me key feedback on what a low-miles vehicle should feel like....and that is one of the treasures about the G-Wagen...the platform is largely unchanged from 2002 to 2014. If you want to know what a perfect 2004 G-Wagen should feel like, just drive a 2012.


I discovered a 2004 G500 through an online ad in the San Francisco Bay Area. I live near Lake Tahoe, so it was a commitment to see it in person. I made the drive, fell in love, and then learned a new lesson. When the lockers didn't immediately lock-up, I feared there was something wrong. They all locked, but things didn't happen immediately like in my Jeep Rubicon with electronic lockers. I walked away from "the one" because I didn't know enough about the vehicle. On the way home, I stopped at a Mercedes dealer in Fairfield, CA to test the lockers on a 2011 G550....they behaved the same way. The following week, I drove back to San Francisco and purchased it before it became, "the one....that got away."


It's a one owner vehicle that was purchased in Nevada and then immediately moved to San Francisco. It has 39K miles. It has the original tires (manufactured in the 50th week of 2003...still with plenty of tread!) and the original Mercedes Battery (Date stamped on the top of the negative terminal.) The interior looks as though it has never been touched and the paint is in unbelievable shape. On the day after getting it home, I removed the running boards....not only were the bolts not rusted or corroded, they weren't even dirty. I'm not sure it has ever been driven in the rain. While it's kind of a drag to immediately need to start spending money on tires, battery, etc, it's something I would have done anyway and the original equipment tells a story on how this vehicle has been treated during it's first 10 years of life. This G500 drives as well as any other G-Wagen I have driven, regardless of age.


Day One:




Later in the day with no running Boards:



After much study and a little luck finding Goodyear Wrangler MT/R in 275 70 18 (5th tire on backorder and will arrive on August 4th):






Upcoming projects:
Odyssey Group 49 battery arrives tomorrow
30mm spacers arrive and will be installed on Thursday
Computer will be changed using the details described on the first page of this thread.... http://www.expeditionportal.com/for...-Sizes-Lift-Height-and-Computer-Reprogramming
Fridge/cargo slide installation
National Luna Powerpack installation


Thanks for sticking with me during a lengthy first post. I promise to keep it more brief as the thread develops, while keeping a log of how things are going. I'm confident this rig will never match the detail of many that are detailed on Expedition Portal, but I'll do my best to contribute when it makes sense.

Also, a big shout-out to Jeremy...he's already been a big help in early decisions. :victory:
 
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Bikeman71

Observer
Wow, she's a beauty! Are you going to de-bling it or leave the appearance as-is?

I'll do a few things like remove the spare tire cover when the 5th tire comes in, powdercoat the bulbar, etc. I probably won't get into a total debadge....those steps often kill resale value when/if the time comes.
 

mk216v

Der Chef der Fahrzeuge
Wow, looking SOOO clean Brent! I'm very happy to hear you went back to retrieve it and didn't let it get away.

You're very welcome for the help, anytime!

PS--I was just reading in the Nat'l Luna PP manual about how they suggest testing the alternator is sufficient. I'd suggest reading/testing--I'll try that soon on mine too just out of curiosity.
 

Bikeman71

Observer
I've been working on installing the fridge and creating useful storage in the rear cargo area. I thought I would share my progress so far.

I started by using brackets attached to a piece of 3/4" plywood with T-Nuts that will attach to the four existing D-Ring attachments...no new holes for this project.


Then I found the best matching carpet available to upholster the board and install in the back....with this solution, I now have a solid platform that can be used to mount anything to the back with strategically placed T-Nuts on the back side.



Then I installed the National Luna Fridge locking plate to a Front Runner storage slide that was made for the Jeep Wrangler....then placed it where I wanted in the back of the G-Wagen and mounted it using 1/4" T-Nuts and bolts.


Finally, I clicked in the National Luna Fridge for a clean fit and finish.


Stay tuned for a future project that will add a second tier of storage just above the fridge.
 

Bikeman71

Observer
In an effort to get my National Luna fridge up and running, a tidy wiring job became the project of the day. I'm waiting to wire in the National Luna Powerpack (second battery) because I want to get a few trips under my belt to make sure I know exactly where it will go. Today, I wired in a Blue Sea fuse box and a Scotty Hella socket...there are many instances where I won't be camped in the same spot for multiple days, and this lightweight and simple option will take the place of bringing along the National Luna Powerpack. I specifically bought the Odyssey battery to make this a suitable option.

I'm using the tool storage area directly behind the battery as my wiring room.



The wires to the Hella socket start at the Blue Sea fuse box, run straight up and under the carpet, then snake across to the jack compartment, where they connect to the Hella socket.



The fridge wire runs under the back seat and to the fridge where there is plenty of slack to allow for a full pull on the fridge/storage slide.
 
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Bikeman71

Observer
gotta ask - what did you end up paying for such a cherry version at 10 years old now?

I'm not going to go into details, but a little less than a new Jeep JKU Rubicon. I'm coming from a fully built 2012 Rubicon, and the build quality is night and day...as it should be for a car that costs three times as much when new. I haven't had it off-road yet. I will be using it mostly for overlanding....Eastern Sierras, Death Valley, etc. I live in Pollock Pines, about 30 miles from the trail-head to the Rubicon. I don't see using it there in the near future...the crowds and overdone party scene have made it less attractive to me...but who knows.
 

dnellans

Adventurer
thats cool - close enough ballpark for me. I just didn't know if choice versions were selling at 80% of new or something more reasonable. Cool to know its same ballpark as a new rubi
 

otiswesty

Regular guy
I like your use of the Euro DIN socket and plug. Nice and snug, secure. I have changed my fridge from the ARB/Engel to the Acutemp AX56L which has built in 12volt batteries and essentially functions as a battery box + fridge. I added more DIN sockets to the fridge side wall and have found a great source for those to be Powerlet products, though they are really more of a motorcycle supply vendor.
 

So-Cal G

Observer
Good stuff on your build, I'm coming from a fully built Rubicon as well. I second the build quality, not even in the same ball park! But I'm not exactly going to bounce this one off the rocks ether!
 

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