I am very satisfied with my '04 E500. One of the reasons I have always selected Mercedes is build quality and safety. I am not an engineer but one can see how massive the pillars and roof rails are. I was T-boned in a 560 SEL in the '80's (not a scratch - insurance company held other driver responsible for running red light and t-boning me). The Mercedes dealership body shop (factory owned) thought a had truck hit my car. I saw the car after it was stripped down and was even more surprised to see how really deep the rocker beams are as well as seeing the asphalt flooring which was hidden under the carpets and padding.
A friend of mine just acquired a 2004 BMW530. He and I have always had our respective motoring allegiance. He boasted that he spoke to a mechanic who services German cars and was told that since the Chrysler merger MB build quality and safety have declined but that the BMW's quality and safety have not.
I personally do not buy this. I know that MB claims to have increased the amount of HSLA steel used in new models. The gas tank was moved to below the rear seat in my model (for years it was directly above the rear axle between the trunk and passenger compartments - I'm not sure if the move was dictated by safety of more trunk space). If I am not mistaken MB offers a full cadre of front, side and curtain airbags as standard equipment on all models (excluding convertibles). last I checked, rear side and head protection were an option on many Bimmers.
What I am very curious about is whether any mechanics or body repair folks, after having seen and worked some post collision versions of the new C, CLK and E-class, had any opinion of the new models structural strength and how they compare with earlier MB models (or BMW's for that matter).
Thanks,
Claude