Bulkhead and Headliner Removal - Budget Van Build Ep3
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- Опубликовано: 5 фев 2025
- 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!
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 🙏🏼😊
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.
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.
LOVE the screencap of the whiteboard and the order of the Screw removals!
Greg is a breath of no-nonsense fresh air in a world of self indulgent RUclips 'van-life' influencers. Love this man ❤
Apart from the van project, it is nice to see the couple working togheter.
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
Excellent detailed video Greg. The Godfather of UK vand builds!
Really glad you liked 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 👍🏼😃
This is the speed of build that I can follow Thanks
Hoping to put out at least a couple of videos a week on individual tasks so it’s easy to follow 👍🏼😃
@GregVirgoe Thanks alot of van builds rush through it to see results fast I guess, no question the finished product is going tode good in your case so Thanks for doing it in full detail
@@karlmabe1649 I see quite a few that show you the end result or a 5min Timelapse but no details of how they built it. This build will include all the details 👍🏼😃
Greg with the best "how-to"s in the vanlife community.
That's very kind of you thank you :D
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 👍🏼😃
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
Good show, you got video of each type of screws and their location. It helps a great deal with sections of each step.
Great i'm glad you liked it
The thing I love about these popular old vans is the amount of in-depth information on RUclips. A couple of years ago when I tried to remove the headliner & overcab shelf from my van I was terrified to do it and there were no videos available at the time so I just left it.
It is a daunting task to take things apart with the fear of breaking parts or not being able to put it back together properly I can totally understand how you must have felt. The step by step videos do make the task so much easier :D
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 😃
Cheers Greg... I've been tearing my hair out trying to get that parcel shelf out from above the cab. Now I know I've to remove the headlining - thanks, what a help this will be to my Ducato conversion 👍
Yes, I don't think you can get to the four bolts near the windscreen with out taking the headliner out, but as you have seen it's not too bad a task and doesn't take long to do. Glad that has helped you
Hello from Croatia,
The videos related to the Mercedes Sprinter were very good, full of details and explanations.
The creation of the Fiat Ducato in the first two episodes is fantastic in my humble opinion. The explanations go into the smallest details.
The person filming should also be praised.
Thank you very much! I shall make sure that Lou reads your comment. Thank you for such great feedback 👍🏼😃
Very interesting project
Glad you think so!
I have learnt a great deal on van builds watching RUclips. 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 👍🏼😃
Van conversion master class.
That’s very kind of you 👍🏼🤩
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 😂
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
Greg, i've just subscribed. I'm from South Africa, and I plan to start a my Ducato or Boxer conversion later htis year. So far, yours is hands down the best instructional videos i have come across. I really look forward to following your build!
Welcome to the channel. I have a lot of useful video from our previous sprinter build that you will also find interesting 👍🏼😃
@@GregVirgoe Thank-you i intend to! I'm going to find a van that fits your instructions, not the other way round!😄... i'm a rank beginner, so this is gold!
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 😂😊
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😂
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. 👍🏼😃
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.
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 🙏🏼
We like science, physics in a van build absolutely perfect, great video Greg many thanks
We have filmed some great ones for you if you appreciate that kind of information :D
I commend your patience. I would have been like, "Here's a driver for the Torx bits... but since I have a impact driver, I'm going to use that..." For everything... including that 13mm bolt.
I look forward to the rest of the build. Slowly catching up on videos I've missed.
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🚐👍
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.
1st class as ever Greg 👍
really appreciate your comment. thank you
Alright for some! On my van, Vauxhall, for reasons known only to themselves, decided to RIVET the bulkhead in place!
Thats a bummer, lot's of drilling to remove it the rivets heads
Always a pleasure to see your videos. Also nice work from Lou.
Thank you, I will pass on your compliments to the camera lady :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 👍🏼😃
very detailed,without skiping minor stuff 👍
Thank you, hope they will be very useful
they will when i find a van!!
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. 👍🏼😃
The van goat does it again, boys!
I really do appreciate your comment 🤩 many thanks 🙏🏼
Excellent video yet again Greg your attention to detail is fantastic 🎉
Glad you enjoyed it 😊thank you for leaving a nice comment.
Take that £1.20 off the budget...ROTFL😂😂😂 Best campervan build videos on RUclips!
Thank you for appreciating my humour 😆👍🏼🤩
Great video about over head insulation. I had condensation running down onto my windscreen from the inside of the roof after I had finished my build. Everyone please do this early on as it is definitely worth it. Cheers Greg
Yes it’s an area that is often overlooked but I guarantee there are loads of vanlifers that have water pouring through their cab lights the next day.
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.
Greg we have watched a lot of video's on youtube and your craftmanship in campervan builds leaves no stone unturned ..me and the mrs have just bought a little lwb high roof ldv maxus to convert so we will be tagging along with this build cheers buddy .
Those LDV vans do look great. Best wishes for your build and thanks for following along 👍🏼😃
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. 👍🏼😃
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 😃
Thanks, Greg. Just made me purchase more insulation and auto carpet to revitalise my gloomy lucking headliner. Wife loves you 😂 I put this job off after hearing it was a pig to do. You have give me the confidence now to tackle it. Cheers bud
It’s really not difficult to do so don’t panic. Sorry I cost your more money 😳☺️
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! 👍🏼
Thanks Greg! I look forward to the insulation vid.
One thing, I've seen people putting a LOT of sound deadening around to make it sound nice, it occured to me this is quite a lot of extra weight! When you do the insulation can you possibly add a note about sound deadening and how much we need / how little we can get away with. Or save it for another video lol.
Anyway, keep it up - your vids are the only proper resource out there for the mechanics of making a van for vanlife. Cheers mate. From New Zealand. You can borrow my van if you come down this way for a holiday.
Yes we have filmed the sound deadening video already and I can tell you I only used 18 small squares on the whole van. 😊 I explain why you don’t need to go mad and show another product that is better to use in certain areas. 👍🏼😃
Greg's Sprinter video series covers this, I can remember him tapping the panels to see how much they resonated.
@@stevesjobsUK Yeah I just watched that one after he gave me the heads up! It's a great series and very well presented.
Absolutely great to have you back to a build video, looking forward to every episode Greg
Thank you Ronan, glad you liked it
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 😃
Loving the new series!
I’m so pleased 😀
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.
Greg, you are a wonderful educator, and the quality of your videos is unmatched.
Your attention to detail is most appreciated. I'm sure it is quite time consuming to go as in-depth as you do, so I hope you keep the videos coming.
Many, many thanks!!
Thank you very much, its nice to know they are appreciated. I do enjoy makign these instructional video but as you indicated they do take a lot more time to film. With comments like yours that makes it all worth while and there will be many more to come.
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
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 as always explained simply and detailed demo. Thanks your videos really help😊
Glad you like them! 😊 thank you
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 👍🏼
Going to get busy with this tomorrow cheers for the content 👍🏻🚐
Excellent video again, Greg. Really well thought out.
Thank you 🙏🏼😃
Well done Greg 😎🚍⚓️🇬🇧👍
Many thanks Roger 👍🏼😃🤩🍻
Well worth the effort Greg. Our first van, a Autosleeper Duetto, suffered terrible condensation problems above the cab. We stored our bed linen there and it was always damp and mouldy, if we left it there during the cold winter months. It had just a single layer of carpet lining. Looked nice but totally useless.
Yes I agree it’s one area that’s often overlooked and can create a lot of condensation on that metal roof. 👍🏼🤩
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.
Great to see a van build from scratch and in sequence Greg, it is going to be very helpful. Thank you.
You bet! This will be more detailed and show every task and how they are done.
The man is back .... and in top form
Thank you very much 😊
Really useful Greg. We’ve got a Fiat Ducato which we had converted based on your van build videos so it’s great to see all the detail. Brilliant RUclipsr Adz Ventures has just bought a Ducato which he is fitting out and I’m sure he’s going to benefit from your tutorials. The adorable Ame In a Van cited you in one of her videos as the ‘go to’ for van conversion. I can’t agree more.
Yes I follow both those guys so it will be interesting to follow Adz progress on his Ducato.
Ame made a great job of her transit build and is a fantastic film maker. Doing very well on RUclips. Thank you for a great comment 😊
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
Nice one Greg, easy to follow as always, good job 👍
Awesome, thank you!
Great video Greg, look forward to the rest
Glad you liked it 😊👍🏼
Great video, appreciate the effort it takes to make this series!👍
It makes it all worth while when they are appreciated so thank you 🙏🏼
Great stuff Greg 👍 👏 👌
Glad you enjoyed it
Great video as always Greg . Ducato is the king of Vans and I've had most makes . Keep up the brilliant content.
It’s a very good van and my preference above the French variant but I must say I still prefer my sprinter to drive 😊
Great detail as always Greg. Good stuff, thanks.
Glad you enjoyed it
instructions made for babies (: clear and with no experience you can do all! thanks Sir!
Trying to make it accessible to everyone 👍🏼😃
Been looking forward to seeing this build !.
I hope the first few videos are worth the wait 😊
As expected, high quality video and informative. Really looking forward to the series
Thank you for great feedback Pete 👍🏼🤩
Very informative Greg. Love the content. See you soon, love to Lou.
Thank you so much, lots of love to you both :D
these vids are so helpful... you're a diamond for taking the time to do em... thanks 👍🏻
I enjoy the channel Greg, probably one of "THE" Best and most detailed campervan build channels on RUclips. 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. 🤩
Excellently detailed Greg! looking forward to the project!!!
Time lapse would be an absolute bonus for this series.
Do you mean a montage of the full build towards the end of the project?
@@GregVirgoe No Greg, a time lapse of the mundane footage such as unscrewing things. Appreciated your including footage explaining things, as an example when unscrewing the bulkhead.
@@UKvet246 ah ok 👍🏼 some of the footage is sped up to 150% as I was aware of that and removed duplicated jobs like sun visors and grab handles. Sorry you didn’t like it 😢
@@GregVirgoe Haven't disliked anything, just an observation on viewing the more mundane tasks.
@@UKvet246 there are buttons to skip forward in 10sec steps. You might find that useful 👍🏼😃
Thank you for doing such clear instructional van build video's and also thank you for keeping things simple
Top job Greg! And nice camera work from Lou too🙂
Glad you liked it! I shall pass on your praise to my camera lady 😊
Superb work Greg, thanks. I'm unlikely to do a conversion myself, but I love seeing how it's done. You're a star.
I really do appreciate you watching especially if you are not doing one yourself. Thank you
@@GregVirgoe Even though at 74yo I'm unlikely to do a conversion, I pick up little DIY tips I might use myself.
I just removed my bulkhead in the Iveco daily and have been scratching my head as to how to trim back to the plastic from the cab around the perimeter of where the bulkhead was. Hopefully Greg will do this later !
I’m really pleased of this series because it’s given me the confidence to start converting in Summer.
They do have the full plastic trims in mini busses and van with no factory bulkhead. I believe Renault master are the same as the daily. Bit rare to find though.
I shall be making mine out of plywood and covering with silver carpet so there will be a video on that soon. If you don’t fancy making them and have a little cash you can buy the full trim kit from Solway solwaycamperconversions.co.uk/online-shop/ols/products/front-shelf-cover-ns-os-b-pillars-3-piece-set-for-ducato-relay-boxer-h2
@@chriscoulthard4947 Thanks Chris, I appreciate the information! Funny thing, you reminded me of when I bought a salvage Movano with headliner removed because of fire damage. The body panels had “Iveco” stamped on~and the Movano is same as the Master.
@@GregVirgoe Thanks Greg. This van is H3,L4 and between the side loading and rear is going to be our pet cages aswe are licensed pet transporters. From the cab back to pillars where the side door finishes I’m going to have a small welfare area for me to rest as we transport from Russia to all over Europe and UK. The rear will need to be washable and extremely well temperature controlled. I will need air conditioning and heating but also a roof fan and diesel night heater to run off leisure batteries in case of breakdowns. Siberia gets to -60 in winter and +35 in summer. No idea what air conditioning to use but needs to be fit for purpose. I’m a carpenter by trade Greg and was making stairs etc in my dad’s workshop since being 12 and can say that your work is as tidy as I have seen from any tradesmen
@@StevenGarvey-ft6sk thank you 🙏🏼 I really appreciate that. 👍🏼😊
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
Great Job, looking forward to the series 👍🏻👍🏻
Thanks! 👍😃
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 👍🏼😃
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. 😊
Hey Greg well thought out and descriptive video as usual. Really good idea to count and number the screws for ease of putting back afterwards.
Thank you. Maybe it’s my old age but I would struggle to remember where they all went otherwise 😂😃
@@GregVirgoe 🤣I know the feeling but totally makes sense for all👍😁
Enjoying watching your van build and the clear step by step detail
Thanks 👍theres many more to come :D
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. 👍🏼😃
I happen to use an egg carton with a top to keep nuts/screws/fasteners separated and in sequence as you did. I number each compartment with a sharpie. Of course, if I have more than 12 groups,I simply employ another egg carton. A camera shot is a good suggestion.
That’s a great idea to keep them separate in a tray 👍🏼😃
Suprised you don't have a sponsor for these videos as they are so good!
I didn’t want to go down that route and lose some integrity with my audience. 👍🏼😊
Looking forward to this series. I am good at taking things apart! 🇨🇦
😂 yes sometimes the putting back together is a bit more tricky 😃
Very helpful especially for me on the removal of headliner - thank you,
All the best. David 👍
You are welcome, glad you liked it.
These videos are really great Greg, I'm soon starting on a Relay conversion and your clear explanation of each stage will be invaluable, many thanks 👍
Thats great, i hope your conversion goes well, thanks for watching
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!