G-Wagen Trail Recovery: Broken Axle, Bent Track Bar & Maxtrax Winching Strategy
October 14, 2025
Witness a rare G-Wagon body-off restoration. From chassis sandblasting to motor reseal, turbo upgrades, and full suspension refresh, see how a 1995 Doomsday Diesel G-Wagon is rebuilt for life on and off the road.
Today we’re giving you a rare glimpse into a body-off restoration of a 1995 Doomsday Diesel G-Wagon. This truck is stripped down to the bare chassis, revealing the structure, suspension, and all the hidden details beneath the skin. The restoration includes full bodywork, chassis sandblasting, motor reseal, and more.
Before lifting the body, every part is carefully removed, labeled, bagged, and organized. Fenders, inner fenders, radiator, pedal box, and the cooling stack are all removed. Seats are sent to the interior shop, while all components are sorted into bins for cleaning, repair, replacement, or repainting.
With everything prepped, the body is lifted off the chassis. This exposes the fully boxed frame, showing why G-Wagons are so strong and durable. Even though this truck is 30 years old, it shares suspension architecture with modern G63 and G65 models.
The bare chassis undergoes full sandblasting and coating. All suspension bushings, mounts, springs, and shocks are replaced with Fox 2.0 shocks and 2-inch lift springs. Motor mounts, pickup points, and all hardlines are refreshed. Stainless braided brake lines and new hardlines ensure full functionality.
The OM 603 six-cylinder turbo diesel is completely resealed. A larger pump and upgraded turbo improve performance. The labyrinthine exhaust system is replaced with a 3-inch downpipe, muffler, resonator, and side dump for improved cooling and efficiency. Soft lines, gaskets, and fuel injector lines are all replaced for reliability.
Rust-prone areas, especially at rear frame mounts and spring mounts, are cut out and replaced with fresh Mercedes sheet metal. Brake proportioning valves on early drum brake models are checked and bypassed if necessary. Full attention to detail ensures longevity.
Converting from civilian to professional/military-inspired style requires removing carpet and applying a gloss coating to the floor. Minor corrosion is treated with rust reversal agents for a pristine finish. Full access allows flawless restoration and assembly.
Once the body and all components are restored, the G-Wagon is reassembled. Motor, transmission, transfer case, axles, and all chassis components are refreshed or upgraded. The end result is a fully restored, high-performance Doomsday Diesel G-Wagon ready for both daily driving and heavy-duty adventures.
All removed and refurbished parts are available for purchase on nothingb.com. From fenders to rock sliders, headlights to wheels, enthusiasts can grab quality components from the shop’s inventory.
This Doomsday Diesel G-Wagon restoration showcases the craftsmanship, precision, and care that goes into full chassis and body-off rebuilds. From engine reseal to suspension upgrades, every detail is executed for performance, longevity, and authenticity.
Joe Gocher, Nothing But G’s, ensures every project meets the highest standards—because nothing but G-Wagons deserve nothing but the best.
Get in touch with Joe Gocher and the team at Alliance Auto Care—we’ll get your truck squared away the right way.