Club 80-90 Forums

I removed bulkhead in mine quite easily! I cut down the sides close to the "side pillars", I then hammered the remains of the bulkhead towards the side pillars and ground MOST OF THE REMAINING bulkhead off. The bits left I tapped into the side pillars and sealed over to prevent accidents with sharp edges. I covered the whole lot with vinyl anyway so this was a belt and braces job. The reason I didn't cut all the bits off was that I didn't want to cause any damage to side pillars.
Get back to me if you need more info. Good luck. It is a Hell of an improvement! No more getting wet to get in the back!

I believe the idea is to center-punch the spots and drill them out ... something like 4 or 5mm.

Ian.

i cut the majority out with a grinder/jigsaw and left only about an inch round edges. Then was really easy to get in to drill out spot welds - sure i used a 6mm bit.

okay thanks for your help guys.......a few more questions...........

What would be the least messy way of doing it?

Is it possible to remove the bulkhead without ruining it or the surrounding metal??

can it be removed in such a way it could go back to how it was if need be???

and if i were to drill the spot welds, would the bulk head just pull away from the surrounding metal, or is there more to it than that????

I ask this because i want to do the least damage as poss, in fact none really, and don't really like the idea of hacking away at it with a grinder or a Jigsaw etc
I am weighing up the options first before i can bring myself to change it from it's original spec, as it's got some history being an Ex- US Airforce van and only has 66k on the clock. and i am still usure whether i should change her in anyway at all.

MattyGreg05 wrote: and if i were to drill the spot welds, would the bulk head just pull away from the surrounding metal,

Allegedly

Ian

One thought....
Original panel vans without windows hacked in them and factory bulkheads are bloomin rare now... any that were "used" as works vans would have had a hard life and not around.. many have been turned into home brew campers etc... when was the last time you saw a nice original bay window panel van..

Just my opinion of course... ... I'd try and live with it without making irreversable (or expensive reversable) changes.... but it is your van...

Oh, you can get a special drill bit for cutting spot welds that apparenly does less damage....

toomanytoys has a point. If you like he van as it is then why not buy removable camping interior, rather than hack the inside about. As for making it a walk through........ well I can't think of a negative regarding making it a walkthrough, apart from the obvious (spoiling the originality).

Its not too hard I've done it.
Get a proper drill bit for removing spot welds . But beware its also tack welded for some bizare reason.
Mine was a half bulk head my friend has one with a full bulk head .
Removed mine in a couple of hours sprayed up all the grinder marks with a can after, loads better and loads more room .
Do it.