Created 2nd Jan 2012 Revised 26th Jan 2012 Page 1 of 5

W220 2003 Update S500 LWB

DIY Manufacture of Missing Headrest Adjuster Button
Brian W. Rice
1. The Problem
My 2003 W220 S500 as purchased had a missing RH Headrest Adjuster Button. New or second
hand buttons were not available and the whole EAS (Electrically Adjusted Seat) module was
approximately $250.

Figure 1 Missing Headrest Button

2. The Solution
Benzworld Poster kcaz007 suggested I should make one.

3. The Method
Here are the steps that I used.

3.1. Step 1
Remove Right Rear Seat Headrest Adjuster Button. (NB Left and Right buttons look identical to
me so if you don’t have electric rear seats use any button that is available.) Button just pulls off
with your fingers.

Figure 2 Remove Right Rear Seat Headrest Adjuster Button

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3.2. Step 2
Inspect the Original Equipment Manufactured (OEM) removed button especially the centring
device.

Figure 3 Inspect the OEM Button

3.3. Step 3
Drill a 3mm hole in a small piece of timber to hold the OEM button. Make a mould using
another piece of scrap timber and plasticine. Sandwich the OEM button between the two and
press into the plasticine. I used nails to maintain the relative position of the centring device.

Figure 4 Make a Mould using the OEM Button as a Pattern

3.4. Step 4
Remove OEM button to reveal negative pattern.
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Figure 5 Reveal Mould

3.5. Step 5
Fill the negative pattern with Plastibond to just above the required level.

Figure 6 Overfill Mould with Plastic Filler

3.6. Step 6
Reinstall the top piece of timber and using the original 3mm hole as a guide drill a 5mm hole
stopping 2mm short of breaking through the bottom of the new button.

Figure 7 Drill 5mm Ø Hole Part Way Through

3.7. Step 7
Remove top piece of timber.
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Figure 8 Split Mould

3.8. Step 8
Remove moulded button and inspect prior to sanding of rough edges.

Figure 9 Rough Cast Replacement Button

3.9. Step 9
Clean up moulded button ready for painting.

Figure 10 Sanded Replacement Button

3.10. Step 10
Spray paint with Satin (semi-gloss) Black Paint.

Figure 11 Painted Replacement Button

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3.11. Step 11
Compare OEM and moulded buttons.

Figure 12 Replacement Moulded Button and OEM MB Button

3.12. Step 12
Apply a small amount of Plastibond in the hole as an adhesive and fit to car.

Figure 13 Replacement Button in Seat Control Module

3.13. Step 13
Stand back and admire your handiwork. The moulded button is just like a bought one only much
cheaper!!