Mercedes-Benz G400 CDI – Complete Frame-Off Rebuild
Mercedes-Benz G-Class Full Frame-Off Rebuild
Project Overview
This is a full ground-up rebuild of a 2002 Mercedes-Benz G400 CDI – one of the most demanding restoration projects in our workshop to date. The vehicle arrived in severely deteriorated condition: virtually no component was left intact or undamaged. Every single part required either repair, repainting, galvanizing, or outright replacement. All bolts throughout the build are being replaced with stainless steel hardware for long-term corrosion resistance and reliability.
Initial Assessment – The Condition It Came In
The G400 CDI was in a truly alarming state. The overall impression was that every component had been deliberately left to rot. Rust, breakage, and wear were present throughout the entire vehicle without exception. This was not a car that needed a refresh – it needed a complete rebuild from the ground up, starting with the most critical structural component: the frame.
Frame Restoration
Work began with the frame, which was stripped down, thoroughly inspected, and fully restored. All parts requiring surface treatment were sent for painting or galvanizing as appropriate. With every fastener upgraded to stainless steel and all structural issues addressed, the frame was brought back to full integrity and made ready for body installation.
Axles & Brakes
Both axles were in critical condition and required complete overhaul. One axle was broken; the other had corroded to the point of developing holes through the metal. Both were fully rebuilt. The braking system was also comprehensively overhauled and brought up to proper working order. With axles and brakes completed, the running gear foundation of the build was solid.
Body Preparation
With the frame ready, attention turned to the body. All body components were inspected and brought into proper condition ahead of the next stage of assembly.
Full Noise & Vibration Isolation
Complete noise and vibration insulation of the body was carried out – a core part of the build philosophy at OXP Motors. The primary objective throughout this process was to preserve the original, authentic G-Class character and style while delivering a significantly more refined and comfortable driving experience.
Assembly – Engine, Grille, Bumper & Steering Wheel
With the body fully prepared and insulated, major assembly work commenced. The engine was installed, bringing the G400 CDI powertrain back to life. A custom handmade grille was fabricated and fitted, followed by a handmade front bumper – both pieces crafted in-house to complement the vehicle’s rugged, original aesthetic.
