Bulkhead and Headliner Removal - Budget Van Build Ep3
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- เผยแพร่เมื่อ 28 ก.ย. 2024
- How to remove the Bulkhead and Headliner in a Fiat Ducato, Peugeot Boxer, Citroen Relay or Ram Promaster. Ready to insulate the over-cab roof with self-adhesive closed-cell insulation to prevent condensation from forming.
In this video, we give a detailed step-by-step walkthrough of how to remove the bulkhead and headliner. We show you what tools you will need and give you a few simple tips to make the job very easy to do.
The tools we used in this video are listed here :-
Plastic Trim Clips Removal Tools www.ebay.co.uk...
Allen Key Set www.ebay.co.uk...
TORX key set www.ebay.co.uk...
Plastic Push Fasteners Panel trim clips www.ebay.co.uk...
Disclosure - As an eBay Partner, I may be compensated if you make a purchase using the above affiliate link. Thank you for supporting our channel.
Please do consider subscribing to this build series as we will be going through every part of this build in great detail. With lots of bonus information and free tips and tricks along the way.
Please leave us a comment and share your thoughts on this budget build.
Thank you for watching
Greg & Lou
#fiatducatocamper #offgridliving #selfbuildcamper
Greg, you are the clear leader in instructional videos. Your straightforward approach and ability to break down the work into manageable chunks accompanied by clear explanations of each stage will be a godsend to self builders. Can‘t wait for episode four..👏
I appreciate that! Thank you for such great feedback. Makes it all so worth while 👍🏼😃
Yes indeed, great !
Well said. I feel more confident to know where to start. Great and very helpful Many thanks
Spot on. I've binged watched so many of these videos!
Greg is a breath of no-nonsense fresh air in a world of self indulgent TH-cam 'van-life' influencers. Love this man ❤
This is going to be the encyclopedia britannia of Ducato builds. Superb!
Hope it will help many different van varieties 😊
@@GregVirgoe Absolutely. It's really helpful to see all the steps broken down, and then you can just apply them to whatever your van has. Priceless resource in a brilliant format. Thanks Greg and Lou.
@@vanforallseasons thank you guys. We really do appreciate you and makes the whole process so worthwhile 🙏🏼😊
A van build bible in the making. Top work Greg
I hope this series goes on to help many others that want to take on a self build.
Apart from the van project, it is nice to see the couple working togheter.
I have learnt a great deal on van builds watching TH-cam. The one person I turn to if there's anything I'm stuck on or don't understand is Mr Greg Virgoe. Simple and understanding ways of doing a van build. Thank you so much for providing me and the rest of us van builders and none van builders who find your videos really enjoyable. You're an inspiration to us all.
Thank you very much for such great feedback. Really pleased you find the videos helpful 👍🏼😃
Loving the new series!
I’m so pleased 😀
The next one's gonna be full of R-values?
I really enjoy the focus on under construction/technical stuff/etc. The window expert was awesome!
Keep up the great work, Greg! Always excited to see what's going on in your builds
To compare thermal insulation properties you shoudl really look at the K value :D lol
I'm sure you will enjoy the extra information on the next ones. Thank you
@@GregVirgoe K - R close enough 😂
Thanks Greg looks like your doing a really comprehensive video series
Glad you think so! It’s my plan to make this series much more detailed than before. 👍🏼😃
Nice one Greg, easy to follow as always, good job 👍
Awesome, thank you!
Very informative Greg. Love the content. See you soon, love to Lou.
Thank you so much, lots of love to you both :D
Let's go Greg!! I think I found £4 odd when I took out my bulkhead 😝
It’s a great feeling to get that little bonus 😂😊
Great detail as always Greg. Good stuff, thanks.
Glad you enjoyed it
Your the man for us novice campervan builders
Keep up the good work and your way of explaining is just the job. Thanks Greg
Than you very much Les, Much appreciated
Thanks Greg, for this video. I am in fact at this stage now as just have the cab headlining to reupholster myself. Done the door cards and gear stick gaiter. Seats are now done . A lot of bolts and a must to ensure a good insulation above their. As during the winter this area was running with condensation and ice . This has led to moisture on my headling causing black spots. I was going to use the kirivans 8mm closed cell acoustic thermal liner with silver face .
Many thanks Greg
Yes I totally agree. 👍🏼😃
Looking forward to the next video - I like it when you do science,👍
I’m putting out some rust repairs to the floor first as that’s the order it was filmed but after that is more facts and figures. 👍🏼😃
These videos are superb Greg, as always. Hopefully get to meet you one day at one of the van meets.
Thanks you Neil, I look forward to seeing you 👍🏼😃
Well done Greg 😎🚍⚓️🇬🇧👍
Many thanks Roger 👍🏼😃🤩🍻
Greg, your videos are fantastic, have to say you are so brilliant at explaining all the steps and processes that are needed during a van build. Love that you also supply tips on where to buy things, how to do things etc... really enjoying watching this van build series.
Thank you 🙏🏼 I’m glad you are enjoying them 😃
I enjoy the channel Greg, probably one of "THE" Best and most detailed campervan build channels on TH-cam. Its good to refer back to when doing a build as a kinesthetic learner I need to be touching and doing. Whereas my wife would prefer a book format.
You should run a basic maintenance, insulation, electrics course. Very basic but allows for people like me to take on the information differently.
Anyways, hurry up and finish the build so we can see you and Lou of somewhere nice abroad.
Keep well pal
Hi Callum, I would really be interested to hear more of your thoughts about the different learning methods you suggest. 🤩
these vids are so helpful... you're a diamond for taking the time to do em... thanks 👍🏻
Love the fixing cataloging, very helpful 👍
I can think of anything worse than removing everything chucking it in a box then struggling to remember what went where and ending up with screws left over 😂
Glad it was helpful! 👍🏼
When removing the bulkhead on my Mercedes Citan to make a mini camper there was a few tamper resistant bolts. Usual trick with a hammer and a small cold chisel on the side of the head had them out in no time. Following your videos with great interest as looking to get a mwb Ducato for my next build, have a lwb Crafter at the moment and want to downsize, slightly.🚘
I did the bulkhead on a 2015 Ducato and it had some of those, surprised to see there weren’t any on this one, suspect the bulkhead was taken out before seeing as the plastic shelf had been cut.
I just did this same job last month with 2 layers of 20mm closed cell foam - I should have waited!
That will be really well insulated up there with 40mm of closed cell. good job :D
Super helpful to see the process step by step. Thank you !
Top job Greg! And nice camera work from Lou too🙂
Glad you liked it! I shall pass on your praise to my camera lady 😊
Loving the new video series Greg. A Good, honest, step by step detailed breakdown….a pleasure to follow mate….looking forward to the next stage👍
Awesome, thank you! Hope you continue to enjoy this format. 😊
Brilliant! Loving this series. This level of detail is so important for those of us who need all the help we can get.
That’s great I will make sure to pack as much useful stuff into them. 👍🏼😃
Your videos are incredible. Educational, inspiring and great fun to watch. Please keep doing them for many years
Thank you so much 😊 really is appreciated 👍🏼
That van is making you money already
We all need money to live, luckily living fulltime in a van you can do that quite economically
Hi Greg, Started re watching this budget build must be my 3 rd time watching ,so Informative...As for me still saving up for a van ,only got 2 k to date so a long long way for me to go ;hopefully within 2-3 yrs I’ll get a van I can afford ,sounds daunting 2-3 yrs . I ll keep the faith /watching. Seen your video with Mel ‘s big van small world grt . Keep safe🏴
Hi Greg 👋 great to see you back again with this van build 👍 will be following yous again 👍👍👍🇬🇧🇬🇧🇬🇧🚌🚌🚌
Thank you very much great to have you back too 👍🏼😃
Very helpful especially for me on the removal of headliner - thank you,
All the best. David 👍
You are welcome, glad you liked it.
You couldn't have timed this series any better as I have just purchased a citroen relay L3 H2, which I am going to convert . Really appreciate the detail you go into. Keep up the great videos.
Great to hear! There are loads more videos already filmed in this series so plenty of good information.
Pleasure to watch your all videos van conversion or traveling always interesting thank you Greg .
Thank you 🙏🏼 I’m pleased you like both formats. The travel ones are not as popular and I find them hard to make interesting so I’m glad you like them both 😃
Excellent tutorial. Thank you.
Glad you enjoyed it!
Enjoying watching your van build and the clear step by step detail
Thanks 👍theres many more to come :D
Thank you for doing such clear instructional van build video's and also thank you for keeping things simple
looking great this new build Greg👍
Glad you like it 👍🏼😎
Well done greg. You must be so chuffed with the reaction to your video. I swear you will likely receive several proposals by weeks end and all you did was take a few bolts out. Imagine when you start on the tricky stuff... 😂😂😅😅
I was nervous about just put out what is basically a strip out video but am so grateful for the comments. There is so much more tech stuff to follow on 👍🏼😃
Another great informative video from Greg & Lou. Keep up the good work. I'm looking forward to the next one.
Thank you Dave, hope you are keeping well. Give our love to Fiona and the pooches :D
Very interesting project
Glad you think so!
Very helpful again. Thanks.
I’m glad you like it 👍🏼😃
Greg, this is great as always. As I’m looking for a Ducati LWB to start my own build your videos will be valuable to make sure I don’t make any expensive mistake. Keep up the good work.
Thank you, best of luck to you finding your new van
Bringing back fun memories ❤😂
Thank you for watching. Is your own van finished now? 😊
@@GregVirgoe no not yet just started the overhead cabinets, then onto the Kitchen🚐👍
As expected, high quality video and informative. Really looking forward to the series
Thank you for great feedback Pete 👍🏼🤩
Excellent Greg thank you 👍
Glad you enjoyed it 😊
Just noticed there is a torx tool that fits the bulkhead in the Jack box under the passenger seat. I have 17 plate Boxer.
Love the content Greg, would probably not have the confidence to do a van build without your videos!
Superb. Thank You.
You're welcome :D
Another great video, helped me with taking the liner out of my 2015 LWB. While not exactly the same you've definitely made it a lot easier for me.
That’s really good news. It can be a daunting task but taken in steps it’s doable 👍🏼😃
Hi Greg, Many thanks for doing these. I'm currently building a 2018 L3 H2 Boxer and are glued to your previous videos which I am finding very helpful. My build has just started so they could not be better timed. ;-)
Thats excellent, a lot of the details of this van will be identical to yours so hope that helps you too
The van goat does it again, boys!
I really do appreciate your comment 🤩 many thanks 🙏🏼
That’s grand, thank you so much.
You're welcome!
Van conversion master class.
That’s very kind of you 👍🏼🤩
instructions made for babies (: clear and with no experience you can do all! thanks Sir!
Trying to make it accessible to everyone 👍🏼😃
Brilliant. Thank you :)
You are most welcome 🙏🏼
Very good video if there all like that it will be brilliant
Yes, thanks that’s the plan. Make them as detailed and easy to follow as possible. 👍🏼😃
I replaced the plastic tray with a ply panel to get rid of the front lip. I also covered the headliner with stretch carpet at the same time. I wish my centre light came out as easy as yours did. Mine was a pain.
Some had the light out previously as it wasn’t put back right so it pretty much fell out. How did you fix the plywood shelf?
@@GregVirgoe I cut it down the middle and attached it to a central strip that I attached to the metal cross member. It won't go in on one piece.
You will need to mount two blocks in the outer corners using Sikaflex too.
thanks greg
You’re welcome ☺️
A little tip for anyone out there. Try selling your bulkhead before getting rid of it. I put mine on Facebook marketplace and managed to get around £30 for it👌 a lil bit of seed money for your conversion😉 I honestly thought no one would want it, but tried it anyway and it was gone within a week!
You were very lucky indeed 🤩
@@GregVirgoe😂😂😂😂😂
Take that £1.20 off the budget...ROTFL😂😂😂 Best campervan build videos on TH-cam!
Thank you for appreciating my humour 😆👍🏼🤩
Loving this series Greg, we’re both enjoying watching . Hopefully we might actually learn something 🤣. Just considering what to do with our transit custom so we can go ‘van lifing’ again . Hope you’re both ok x
Hello Tina, nice to see your comment here 😊
Is your transit an empty van in need of converting? They make great day vans with lots of options on the market for kitchen units and pull out beds. Say hello to Nigel for me. Cheers 🍻
Yes just a swb transit custom so it’s Nigels daily car and can do for us camping until he retires x I’ve seen 3 designs how we could do it , now to choose the right one is the difficult bit lol x fascinating to watch this build though it’s great viewing thanks Greg x love to you both x
Greg, looking forward to hopefully having more videos in this series soon?
Like to see the headlining retrimed in Alcantera
oooh that is a bit posh :D isnt that what they used on old Lamborghini Countach interiors lol
I use the spanner on the Torx bits but prefer a short bit of tube as they don’t slip as much. Those Torx ends are ROUGH on your fingers though.
Yes the right size tube would be a better option. Thank you for that suggestion 👍🏼😃
Great build to watch thanks have you thought about using cork as an insulation barrier also good for preventing damp and mold and a lot lighter and cheaper
It has a few good properties but you’d need to use a separate adhesive to apply it. You’d still have to tape and joins or edges and would need to use multiple layers to get close to the thermal properties of PIR board.
You were lucky £1.20, I got 2 hula hoops and a pen 😂
Lol that is so funny 😂 😊
Hi Greg- great videos! Its been inspiring to watch and has given me confidence to have a go. Having removed the bulkhead do I need to plug all the holes at the bottom? Been under the van and can't see whether they go through to the underneath or into a dry/contained space?
That cut shelf almost makes it look like a previous owner may have used the headlining to hide something, I wonder if it was in Dover 🤔
it's totally baffling why some would cut that out but my only guess was he needed to put something long in the full length of the van that didn't fit over the shelf so cut it out.
3:30 Have you ever seen him move so fast?
LOL :D thats funny
Just use that cordless Driver for every Screw & Bolt , did you not advertise the Bulkhead for Sale Greg, Sell it st the local scrap Yard Weigh it in.
Did you see on My els Channel about Cork insulation, All Natural , No moisture or Mould Build up ,Sound deadening too .
Good Build series 👍
I’m using all tool options for those that don’t have access to power tools to give more budget options.
Yes I saw the cork but to be honest it’s not the best option. 👍🏼😃
@@GregVirgoe what is then ?
Hi Greg, is there a follow on video to this where an over cab shelf / housing is built? Thanks
Hi Greg, great video. How was the job pitting it all back in?
Hi Greg do you already have a buyer lined up for the Van after it is completed? If not, we would be interested. Cheers
A few people like yourself have expressed an interest but nothing is agreed so please do contact me by email which you can find on my about page www.youtube.com/@GregVirgoe/about
🎉
Cheers 🍻
Can the shelf be removed entirely? I would like to install overhead bed.
How did you source the Ducati Greg? You paid a very reasonable price for a relatively low mileage van in this condition. To echo other comments; first class tutorials. ATB Greg.
I set up an email notification on eBay for new listings of Fiat Ducato vans. As soon as I got the email I rang the dealer. Just jumped on it immediately as soon as the ad went out. It was a car van dealer in Northamptonshire 👍🏼😃
@@GregVirgoe Thanks Greg! You’re a top bloke.
@@Hiker1958 no problem 😉 anytime 👍🏼
Hello. Where is the finished version of campervan?
Greg. A quick question. I brought an Iveco van. And when I told my mechanic (that was checking over the van for me) my plans to chance the fronts seats over to swivel seats. He said that I had to get permission from Iveco to do this before or it wouldn't cover on my insurance?? Any advise / info about this please?
My 2018 Boxer had two round head bolts about halfway up on either side of the bulkhead. I cut a slot in the heads with an angle grinder and used a big screwdriver to remove them. Why Peugeot find it necessary to use so many fixing types for one panel is beyond me!
I have a plastic shelf you can have... I took mine out and built a storage bit out of ply..
Hello Stephen, can I ask what age was your van as the newer ones are a different shape at the back? Thanks
I have a 2016 peugeot boxer.
Have you fitted a roof fan have h missed the video
You havent missed the video, that has been filmed and will be out very soon. stepping up to a couple of videos a week to get the content out quicker. :D
Thank you don’t know if you realise this but all the best van builds refer to your content well done 👍
Nice mate. Thx. :)
You’re welcome 🙏🏼
First
Awesome 🤩 we’ll done 👍🏼
Where do you want your medal sending?
Greg, did you remove the cross beam at all?
No that all stayed in when the headliner went back in 👍🏼😃
As a Peugeot main dealer mechanic I advise you to renew the seal, sealer on the base of the roof aerial while the lining is out. These leak a lot over time . I’ve removed plenty for water ingress.
Keep it up Greg .
Thank you Jordan I did have a good look at the when we had the liner out. Thank you 🙏🏼
Good tip Jordan, Ill look on my Boxer when I get there
Yep. Had mine resealed last year. The interior lights had gone on the blink and the leak was the issue.
interesting I've had a couple of times water spill out from the midroof area onto the dash...mechanic said condensation.... sounds like it might be this... hopefully I can still take headliner off as I have already converted with a ply bulkhead.
@@yogagirlexmouth166 it can be either if you are staying in the van at night and have not insulated the cab roof. That does condensate a lot in cold weather.
Thanks for your time and expertise Greg I'm sure it be much appreciated. This will be a beneficial series for new builders and those who perhaps looking for ideas to improve there build. Otherwise great source of info and confidence for those wishing to build their own camper. 👍
My sim is to break these tasks down into easy to follow guides that anyone could feel confident taking on. I’m really grateful for your kind feedback 😃
Greg please keep this level of detail in future videos. It'll be invaluable if I ever get the confidence to do a build myself
Thank you for the vote. That's the plan! I will put in lots of useful detail 😃
You could also use your hex and torx bits with your socket set to get more leverage and speed thing up.
Here in the Black Country we would put the bulkhead at the end of the drive and the tatters would take it away before you could say scrapyard.
Yes i do have a holder that would take bits in the socket set. :D
Looking forward to the insulation probably one of the most important aspects of the van build ..
We’ll be looking at more science and new products with this build.
Back when we followed your first build, it became clear to me that you have ‘that’ knack of being able to present information in its simplest form. Our build was only as successful as it was due to you Greg. Yet again, your knowledge comes into its own. Laying out the fixings following the bulkhead removal and in the order removed. Brilliant, thank you for sharing Master Yoda of Yoda’s 👍👏😊
its really nice to hear that the videos have helped you to build your dream campervan, that makes me happy. Thank you for following us and wish you lots of happy travels in your van :D
I remember watching a lot of your epic camper build in the past and you're an excellent teacher. Look forward to seeing this progress.
It’s great to have you back on here watching this new series. Thank you 🙏🏼
Excellent video yet again Greg your attention to detail is fantastic 🎉
Glad you enjoyed it 😊thank you for leaving a nice comment.
Third !!!!
Greg as always explained simply and detailed demo. Thanks your videos really help😊
Glad you like them! 😊 thank you
you could use the headliner for manufacturing the guard under the engine, if your vehicle does not have one.
Really useful as I have a few jobs on my Ford removing panels and always scared on how to do it without damaging the panels so great tips for a novice
Glad it helped, the trim removal tool really helped to get the plastic clips out without breaking any.
Just doing my L3H2 Boxer. This video was great , saved me working it out for myself 😊
Great videos, hoping you stay ahead of me in your build😂
Greg, on this new project, what have you learned from your first project that you are carrying forward to this project? What improvements do you think your care going to incorporate?
Firstly, I love this methodical & logical breakdown of how you work Greg (just what beginners need), secondly, (and annoyingly) Im going to have to step away from making/negotiating an offer for the completed campervan, the reason is solely London mayor Sadiq Khan with his stupid ULEZ expansion proposals.
Yes this is Euro 4 but on the bonus side it has not ad blue or DPF to worry about 👍🏼😃
Yet my 2,8 diesel iveco doesn't even have a cat but the emissions are as low as a dpf vehicle.
@@chriscoulthard4947 yes modern additions to diesel vehicles just add more things to go wrong.