Purpose of the Installation Overview
This article provides a general installation overview and technical background for composite bulkheads used in Mercedes-Benz Sprinter W907 vehicles. It is intended for professional installers, fleet operators, and van builders evaluating partition solutions.
Installation Concept
With our composite extended bulkhead we wanted to carry the Neomatic philosophy of developing complete solutions with minimal assembly and modification requirements. To achieve this we reused the original Mercedes-Benz bulkhead mounting positions and hardware. In a case where a bulkhead has been fitted from factory the mounting holes are already present in the van body and no drilling will be required.
Our mould design is such that the mounting hole locations are transferred from the mould to the product and we predrill these holes during production so that the customer install is fast and clean. As the original Mercedes-Benz mounting screws are reused the job becomes a simple bolt-off and bolt-on process.
The mounting process can be completed without any other modifications or part removals. We do suggest considering the removal of the passenger seat for easier access to the lower mounting screws, but the bulkhead can be installed with the passenger seat in place.
Mercedes-Benz Sprinter Extended Composite Bulkhead mounted using OEM screws
Corner plates
Regarding the small OEM corner plates we decided to split the solution. For customers switching from an OEM bulkhead to our design there is no need to replace these plates and the originals can be reused. For customers going from a no bulkhead setup to our extended bulkhead we offer the small corners as composite parts as well.
Right side corner OEM plate mounted along with extended bulkhead using OEM screws
Typical Installation Steps
OEM bulkhead removal
Removing the OEM bulkhead is a straightforward process and does not require any special tools. The mounting screws must be removed from the cargo space and also inside the cabin on the lower edge of the bulkhead. For easier access the passenger seat can be removed but in many cases it is not worth the effort and the screws can be accessed with the seat in place. Once all of the screws are removed the bulkhead is easily lifted out of the van by two people.
Composite extended bulkhead installation
The installation process is the reverse of removal with one small difference. In a case where the replacement bulkhead has been ordered without the corner plates these must be transferred over from the OEM bulkhead. If the plates have been ordered along with the replacement bulkhead they must be first fitted to the bulkhead before fitting the bulkhead into the van.
Once the corners are sorted it is a simple job of lifting the bulkhead into place and starting to insert the mounting screws into the predrilled holes. The bulkhead can be aligned easily using the mounting holes. We suggest first using one screw in each corner to position the bulkhead and then screwing in the rest to fit it firmly in place. Use of a flashlight or torch in the cabin when installing the lower mounting screws can be helpful.
The install can be completed by two people in under an hour, possibly faster with experience.
Lower mounting screws observed from the cabin during mounting
Condensed overview
- Unbolt the OEM bulkhead
- Install corner plates to replacement bulkhead
- Bolt in the new bulkhead
- Done in an hour with 2 people
Considerations for Fleet & Professional Use
Production Scale
Due to our focus on composite parts production and strong partner network we can reasonably scale production to match larger fleet sizes and deliver orders on time while maintaining quality. We are open to customization for larger orders but these matters are discussed and priced on a case by case basis. Customization options include but are not limited to:
- interior fabric colour
- cargo side color
- cargo side surface finish
- composite layup
- application specific shape adjustments
Documentation
To ease installation and training we can provide detailed installation documentation and handling guidance. This documentation can be provided in different languages and adapted to customer specific requirements.
Quality Management
Each product we produce is assigned a unique part number and tracked through the production process. This allows us to maintain consistency during the lifespan of production and track any inconsistencies to their root cause. Along with this we have developed a composite part specific in house quality control protocol to make sure everything that we ship is of the highest quality.
Safety & Responsibility Notes
Installation should be carried out by a qualified professional. Final responsibility for installation quality and vehicle compliance remains with the installer.
Referenced Products
For more information and orders regarding our extended composite bulkheads refer to the product page.