27 Jun 2025:
Work has begun on the next phase of the build. Before getting into that, a question will likely come up: Why did you get the paint work done before all of the fabrication and engine swapping? Excellent and valid question! The answer was simple: the first body shop had an opening in their schedule to take the car in, and as they only do one or two cars a year, this was the chance to get the car in. Originally, the project was supposed to be somewhat faster, with hope of bringing the car to the Fall Rally 2024. Plans changed, and now it is moving more slowly. Part of that is out of concern for the current finish of the car!
This next phase is all about two portions: one is wiring. Second is interior. The desire was a Crossfire exterior that wraps up a more modern car underneath. To accomplish this, more wiring would have to be run. The overall plan was to use the electrical systems and interior from a 2005 CLK55. As the CLK (W209) is a convertible four seater, not quite everything is needed, but the high points (for the Mercedes nerds out there) are that integration of the full HVAC system, front and rear SAMs, Keyless Go, and modern seats were all requirements. In addition, the entire W209 dash and center console would be used. A quick reading of the tape measure seemed to show that the dash ought to be almost identical in width. That part was actually fairly true. That's where the easy ran out. Let's dive in:
2005 CLK55 beginning to donate its guts to the Crossfire. Lots of wires!
MANY hours were spent pulling the CLK55's wiring harnesses apart. Separating all functions into sub-harnesses took time, but the payoff was that only the wiring needed was retained. Also, it drove decision processes. For instance, originally the thought was to swap everything, including the complete COMAND radio system. Well, shown below is about 90% of the COMAND wiring alone. That drove the decision to decline the use of COMAND, and go with an Android radio in its place. Airbag system will be run by the original Crossfire controller. Just about everything else on the interior will be some variation of W209. The doors will have W209 controllers in them, but the mirrors will not adjust with memory (maybe later). For now, the CLP (PSE) will be retained for the door locks, but that will likely be updated in the future, too.
2005 W209 COMAND Wiring Harnesses
So, starting with a 2008 Crossfire, with its slightly updated interior, work begins. Stupidly, I took no pictures of the interior before I began the project. Instead I am using this picture taken by
@xfClifford of his interior, which is identical, other than being a manual (and a roadster) (and yellow):
2007-08 Stock Crossfire Interior
The project begins by basically ripping everything apart, and jumping straight into the wiring. Some Crossfire specific wiring must be retained, and most will be replaced. Here's how it started:
So it begins! Wiring at this point is controlled chaos. Notice the addition of several bi-colored twisted pair wires which represent added CAN bus wiring for all known, and a few spare runs for future expansion. Over thirty of these pairs were run about the car.
At the same time, the top pad needed to be trimmed to fit. To do that a paper template of the original top was made, and then laid over the W209 dash top.
Many test fittings of the HVAC box were required. Also required major cutting, fabrication and welding of the various sheet metal bits were required.
