How to Remove the Bulkhead from a Van
- Shane Monks O'Byrne
- Aug 15, 2022
- 4 min read
Updated: Feb 27
Most people doing a van conversion will want to remove the van bulkhead to allow more walking space in the van. This also allows you to move freely between the cab and your living space, and lets extra light in through the front windows. In this guide, I will show you the simple approach to removing the bulkhead from your van.
Index
Shane, the founder of The Van Conversion, is a campervan professional dedicated to helping people transform ordinary vans into homes on wheels. He has authored Roaming Home, and teaches The Van Conversion Course, guiding many people through their van builds. Shane also writes The Van Conversion Newsletter, where he shares practical tips and insights. After completing two van builds and living on the road full-time since 2020, he is passionate about sharing his expertise with others.
This post contains affiliate links, which means that if you click a product link and buy anything from the merchant (Amazon, eBay, etc.) we will receive a commission fee. The price you pay remains the same, affiliate link or not. By using these links, you are helping us to continue writing free educational content. To understand our policies on content, affiliate commissions, and liability, please review our Terms of Use.
Note: Did you know you can get a free electrical wiring diagram by signing up for The Van Conversion Newsletter?
What is a Bulkhead in a Van?
The van bulkhead is a heavy sheet of steel that separates cab in the front of the vehicle and the cargo space in the back. They're ubiquitous in panel vans as they're a required safety component, protecting the driver and passengers from loose cargo.
Is it Legal to Remove a Van Bulkhead?
In many countries the van bulkhead is a legal safety requirement on commercial vehicles. However, if you're building a campervan you are likely safe to remove it. In fact, many countries require 'free access' between the cab and the back of the van for registration of the vehicle as a campervan. Check the van conversion requirements in your particular country before removing it.
You can find information on van conversion regulations here:
Irish requirements are in this guide.
UK requirements here.
Australian requirements here.
Canadian requirements here.
US requirements differ from state to state
How to Remove the Bulkhead from a Van
While the bulkhead removal specifics differ from van to van, it is normally a very straightforward process. Be careful when removing the bulkhead, as they're generally very heavy.
How to Remove a Bulkhead from a Ford Transit
In the Ford Transit, the bulkhead is secured to the chassis with several large torx-head bolts (size T-55). When you remove these bolts, you can remove the bulkhead. They are screwed in very tight, so you will need to use a T-55 torx bit with a socket wrench.
How to Remove a Bulkhead from a Mercedes Sprinter
In a Sprinter, removing the van bulkhead is a little different. The bulkhead is secured in place with blind rivets. These differ from bolts and screws in that they're not designed to be removed.
You can simply drill through the centre of each of these blind rivets and the bulkhead will fall out all on its own. To do this, you'll need a good-quality HSS drill bit for drilling through metal.
How to Remove a Bulkhead from Other Vans
The bulkhead in the Renault Master family (including the Opel/Vauxhall Movano and Nissan NV400) are fixed in place with both torx-head screws and blind rivets. You'll need to unscrew the screws and drill out the rivets, as described above.
Bulkheads in the Renault Trafic family (Opel/Vauxhall Vivaro and Nissan Primastar) are fitted with rivets and ordinary hex bolts. The rivets need drilling, whilst the bolts can be removed with a normal wrench.
In the Fiat Ducato family (Citroen Jumper, Peugeot Boxer), the bulkhead is fitted with hex bolts, torx screws, and roundhead bolts. The hex bolts and torx screws are removed simply, as described above. The roundhead bolts need to first be cut with an angle grinder, giving them a slot like the head of a screw. You can then use this slot to unscrew them with a flathead screwdriver.
The bulkhead in VW Transporters and Crafters is secured with torx screws, making for a very simple removal.
Conclusion
I hope you found this guide to removing the bulkhead from your van useful. You are well on your way to a beautiful self-build campervan. Your next step might be to check your van for rust before starting on the sound deadening and insulation.
Don't forget to subscribe to The Van Conversion Newsletter for everything you need to get started with your own van conversion (we'll send you a free wiring diagram when you join).
If you're looking for some guidance with your van conversion, you might be interested in our book Roaming Home, or in our online course The Van Conversion Mastery Course. You'll learn directly from our founder Shane how to convert a van into your dream home - no prior experience needed. Shane also offers one-to-one consultations, where he'll help you with any aspect of your build in a face-to-face video call. All consultations come with a free copy of Roaming Home and our Diagram Pack.
Finally, our Van Conversion Ultimate Guide lays out the whole van conversion process in easy-to-follow sections with tools, materials, and step-by-step instructions. It's the perfect companion for your van build.
Until next time.
