How to Remove Ford Transit Custom Bulkhead: The Ultimate DIY Guide

The Ford Transit Custom is a versatile van, but its bulkhead can sometimes feel like a barrier to its full potential. Whether you’re looking to maximize cargo space, create a mobile workshop, or simply want a more open feel, knowing how to remove the Ford Transit Custom bulkhead can be a game-changer. This comprehensive guide will walk you through the process step-by-step, equipping you with the knowledge and confidence to tackle this task.

Understanding the Bulkhead and its Purpose

Before we dive into the removal process, let’s understand what the bulkhead is and why it’s there in the first place. The bulkhead is a solid partition that separates the cab from the cargo area. Its primary functions include:

• Safety: The bulkhead acts as a barrier in case of an accident, preventing cargo from being ejected into the cab and potentially injuring the driver and passengers.
• Structure: It provides structural support to the van, contributing to its overall rigidity.
• Noise Reduction: The bulkhead helps to isolate the cab from the cargo area, reducing noise and vibration levels.

Assessing Your Needs and Options

Before you start removing the bulkhead, consider your specific needs and the options available to you.

• Partial Removal: If you only need to increase cargo space slightly, you might consider removing the upper section of the bulkhead, leaving the lower portion in place for safety and structural support.
• Full Removal: If you need maximum cargo space or are planning a major conversion, you’ll likely want to remove the entire bulkhead.
• Replacement: If you’re planning a complete conversion, consider replacing the factory bulkhead with a custom solution, such as a lightweight aluminum bulkhead or a sliding partition.

Gathering the Necessary Tools

To remove the Ford Transit Custom bulkhead, you’ll need the following tools:

• Socket Set: This will be essential for removing the bolts and nuts that hold the bulkhead in place.
• Wrench: A wrench will be useful for loosening and tightening nuts and bolts.
• Torx Screwdriver: Some bulkheads may use Torx screws, so having a Torx screwdriver is essential.
• Safety Glasses: Always wear safety glasses to protect your eyes from debris.
• Gloves: Wearing gloves will provide protection from sharp edges and potential rust.

The Step-by-Step Removal Process

Now, let’s get down to the nitty-gritty:

1. Safety First: Park your van on a level surface and engage the parking brake. Disconnect the battery to prevent accidental electrical shorts.
2. Locate the Fasteners: Carefully inspect the bulkhead to locate all the fasteners holding it in place. These are typically bolts, nuts, and screws.
3. Remove the Interior Trim: Start by removing any interior trim panels that are attached to the bulkhead. This will give you better access to the fasteners.
4. Remove the Fasteners: Using your socket set and wrench, carefully remove all the fasteners holding the bulkhead in place. Work slowly and methodically, making sure you don’t lose any parts.
5. Disconnect Electrical Connections: If your bulkhead has any electrical connections, such as for a rear window or cargo light, disconnect them carefully.
6. Lower the Bulkhead: Once all the fasteners are removed, you can carefully lower the bulkhead. Be prepared, as it can be heavy.
7. Remove the Bulkhead: With the bulkhead lowered, you can now remove it completely from the van.

Securing the Opening and Considerations

After removing the bulkhead, you’ll need to decide how to secure the opening. Here are a few options:

• Custom Panel: Create a custom panel to cover the opening, adding a touch of personalization and functionality.
• Metal Mesh: Install a metal mesh to provide a barrier while allowing for airflow.
• Sliding Partition: A sliding partition can offer flexibility, allowing you to easily open and close the opening as needed.

Beyond Removal: Exploring Customization Options

Now that you’ve successfully removed the bulkhead, the possibilities are endless. Here are some ideas to unleash your Ford Transit Custom‘s full potential:

• Mobile Workshop: Transform your van into a mobile workshop with custom shelves, workbenches, and storage solutions.
• Camping Conversion: Create a comfortable and functional campervan with a bed, kitchen, and storage compartments.
• Cargo Space Maximization: Maximize cargo space for hauling large items or creating a mobile retail space.

The Final Touch: A Satisfying Transformation

Removing the bulkhead is a significant step towards unlocking the full potential of your Ford Transit Custom. Whether you’re creating a customized workspace, a comfortable camper, or simply maximizing cargo space, the transformation you achieve will be worth the effort.

Quick Answers to Your FAQs

Q: Can I remove the bulkhead myself, or should I hire a professional?
A: While removing the bulkhead is a relatively straightforward process, it’s essential to have basic mechanical skills and the right tools. If you’re unsure, it’s always a good idea to consult a professional.

Q: What should I do with the bulkhead after I remove it?
A: You can store it safely or even sell it to someone who might need it for their Transit Custom.

Q: Will removing the bulkhead affect the van’s safety?
A: Removing the bulkhead can potentially compromise safety, especially in the event of an accident. If you’re removing the bulkhead, consider installing a suitable replacement, such as a custom panel or a metal mesh barrier.

Q: Can I reinstall the bulkhead later?
A: Yes, you can reinstall the bulkhead later if you choose. Just make sure you keep all the fasteners and hardware in a safe place.

Q: What are some other modifications I can make to my Ford Transit Custom?
A: Beyond removing the bulkhead, you can explore other modifications like adding roof racks, installing a tow hitch, or upgrading the interior with custom upholstery and flooring.