Creating Homemade Bulkhead - 2004 Sprinter

[ZenDriver]

Hi all,

I have purchased a 2004 Sprinter (LWB) that I am converting into a camper for me and the family (3 kids).

The previous owner (mechanic) installed 3 Mercedes seats in the forward cargo area for his kids. It has been signed off at an MOT Centre and DVLA notified.

However, I am looking at the metal bulkhead which was moved back to sit 2.7metres from the rear doors and attached partially to the interior metal of the van (self tapping screws) and partial to batons attached to the interior of the van (self tapping as well)

I don't like it at all. It is uneven and he never had any cargo so he never fully finished it. I wanted to run my idea by you fine people for advice. I am not a mechanic.

- Remove current metal bulk head and batons etc
- Refit a full frame of 25mm batons using rivet nuts instead of self tapping screws into an arch way
- 25mm batons horizontal (1.6m) and vertical (1.9m) within the bulkhead going up and down the archway
- Attach galvanised steel to the new bulkhead skeleton passenger side
- Attach 15mm Russian Birch to the camper van side
- Reinforce the whole thing with a horizontal steel or aluminium bar in front of the steel plate but behind the passenger seats.

That would leave 2.6m (ish in the rear compartment for the camper version.

Is it overkill? Is the horizontal steel bar more dangerous than not having one?

I just wanted the maximum amount of safety available in case the worst should happen.

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front seats ----
Gap

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passenger seats ----
Gap

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40mm-ish horizontal steel tube at waist height ----

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metal bulkhead plate ----

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25mm timber frame rivet nutted to interior metal

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15mm Birch ply ----

Really interested to hear thoughts.

[GreenV8S]

If the bulkhead is separating people from cargo then it needs to be strong enough to cope with a crash. How strong that is depends what cargo you'll be carrying. But a few self tappers will offer very little strength. A bonded and steel riveted seam round the whole circumference of the bulkhead would be pretty strong - welding would be even stronger. Not sure what the horizontal bar would be for, but if it can impact with passengers then that's potentially a problem.

[E-bmw]

Most custom built motorhomes are made/converted using 20/25mm wooden batons & 6mm covered ply.

I would do more, but your suggestions are well over the top, as above the 40mm bar is probably going to cause more problems than it solves.