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Firstly, apologies for the time it has taken for me to get around to updating the site. I know that a few of you have been very keen to see what I've been doing. Anyway, it has only been 15 months!
Secondly, thankyou to all the people that have emailed me with encouraging words about my conversions and the website. I hope that my answers to some of your questions were of some help.
Back to the conversion: As you can see, I have lined both sides of the bathroom wall partitions with plywood. 6mm is easily strong enough, whereas I used 9mm in the Merc, where weight wasn't so much of an issue. The void spaces were filled with "rockwool" insulation - in these partitions only.
I also ply-lined the "ends" of the bathroom (the sides of the van) and fitted a false ceiling to create a void space about 65mm thick. This being the thickness of the steel roof cross-bracing members.