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Original Sussex Installations video

Thieves making bigger holes in vans and what we do to get this Ford Custom back on the road

Mar 12, 2022 · 11,291 recorded views

Video ID: spGdwcMN_PgAttacks, shielding and repairMar 12, 2022 · 11,291 recorded views

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Jeff Scott’s retrospective context — 2026

As holes became larger, the engineering problem changed again. It was no longer enough to cover one historically common drill point. The repair had to deal with extensive missing or distorted bodywork, while the hidden security still needed to deny access to the latch from several directions.

This is why repair shielding and internal Stealth Shielding should be viewed as separate but compatible layers. The external product repairs, covers and visibly reinforces the door. The internal product protects the mechanism even if the thief attacks outside the visible plate.

The increasing size and destructiveness of the holes also showed how quickly security advice can become outdated when it is based on a fixed attack location rather than on understanding what the thief is ultimately trying to reach.

The increasing size and destructiveness of the holes also showed how quickly security advice can become outdated when it is based on a fixed attack location rather than on understanding what the thief is ultimately trying to reach.

Original description

Thieves seem to be making more damage on vans than ever before and we look at what we can do to adapt to that and design bigger repair shield solutions for our customers so that we can offer them a quick and effective repair solution when the damage on their van is bigger than the normal damage that we see. In this video we have a Ford Custom van in our workshop that has been broken into by thieves making a huge hole in the side load door and attaching the latch (central door) locking mechanism. We cut away the damage and see if our new (very) large side load door repair shield will cover the damage made and get this van back on the road and back to work. Find out more on our website at https://www.sussexinstallations.co.uk

Historical context: This video records the advice, products and attack methods relevant when it was published. Current recommendations may have changed as vehicles, products and criminal methods evolved.

Common questions

Why did you need to develop an oversized repair shield for this Ford Custom?

Because the damage on this van had gone well beyond what our standard external repair shield would cover. Thieves are making bigger, more aggressive holes than we used to see, so I had to design an extended-size shield that reaches further down from the swage line to cover the full extent of the cut and bent metal, without the van needing a whole new door from a body shop.

If the van still locks and unlocks after a break-in, do I still need extra security fitted?

Yes. On this van the latch mechanism still worked, which was lucky since a replacement can run anywhere from about £150 to £400 depending on the year of the van, but driving around with a hole in the door is really an open invitation to a thief to come back and finish the job. That's exactly why we fit an internal shield as well as covering the hole externally.

Does covering the hole with the external shield alone stop the same thing happening again?

Not on its own. The external shield repairs and visibly reinforces the door, but I'd always recommend pairing it with a multi-layer internal Stealth Shield with wrap around the latch features too, since that protects the latch mechanism even if a thief attacks from a different angle to before. I'd also suggest deadlocks and shielding for the rear doors as further layers, not just relying on one product.

Transcript

Show transcript
0:00 -hi i'm jeff from sussex installations
0:02 -today's video is about
0:04 -going bigger look at this
0:07 -damage just getting worse and worse from
0:09 -these vans
0:11 -so
0:12 -i've got something the customer's been
0:14 -in touch with us they've sent us
0:15 -pictures we've seen the measurements of
0:16 -the damage and i guess this is something
0:18 -that's happening where damage to these
0:20 -doors on these four customs and the
0:22 -various different vehicles is is getting
0:25 -bigger and bigger and we're having to go
0:26 -sort of bigger in response to that to
0:29 -give some different solutions so we've External repair shield
0:31 -got
0:32 -our external repair shield which
0:35 -this is a sort of size that it covers up
0:37 -here that's our one which we sell many
0:40 -of and we fit lots of these to vehicles
0:42 -we fit them as repairs when to repair
0:44 -the typical damage when someone pokes a
0:45 -hole through the door to break into the
0:47 -van and also we fit them as like a
0:49 -preventative so so our customers can
0:51 -show that they've got security typically
0:53 -with the internal shield but
0:55 -it's nice sometimes to show something on
0:57 -the outside the van but what happens
0:59 -when the damage that we're trying to
1:00 -cover up goes beyond that shield so what
1:03 -we've done is this is our development
1:05 -door we've taken it and we've made an
1:06 -extended size shield which will cover up
1:10 -a much larger area so if we've got a
1:12 -situation with a vehicle like this one
1:14 -where the damage is got you know they've
1:15 -gone that much bigger that we can
1:18 -actually offer a repair solution and it
1:20 -doesn't need to go to a body shop and
1:21 -have a new door fitted to it you know we
1:23 -can put on a solution we can cover it up
1:26 -and let me show you what we've done What we have done
1:28 -so what we've done we've been in here
1:30 -we've developed and we do actually have
1:32 -this
1:34 -large size shield for a full custom and
1:37 -the idea is that when the damage is that
1:39 -much bigger we can offer a solution we
1:42 -can cover it up so let's go and see what
1:43 -we can do with this van let's see if we
1:45 -can get this van repaired back up and
1:48 -running and back on the road i guess the Does it still work
1:50 -first thing is to see does this van
1:51 -still lock and unlock and open from the
1:54 -outside
1:55 -because
1:56 -typically well a lot of them that we see
1:59 -they don't anymore
2:01 -lock
2:03 -double lock okay locked that's good
2:06 -unlock
2:08 -and it does unlock so i'll just check it
2:10 -from the inside to make sure that it's
2:12 -still functioning
2:14 -like if you're stuck in the van so you
2:16 -can still escape
2:17 -[Music]
2:19 -yeah that's good Cost
2:20 -okay so look at least good news an
2:23 -expensive part sometimes over like 400
2:25 -quid i think for for one of these it
2:27 -depends on what year the van is to how
2:28 -expensive it is but it seems to be
2:30 -between 150 and 400 pounds for that
2:33 -actual ford latch mechanism so at least
2:35 -this vehicle still function if we can
2:37 -put on our internal shield to give it
2:39 -some security against future attacks
2:41 -like that we can put on our external
2:43 -shield to cover up the damage and to
2:46 -give it some more security from attack i
2:48 -mean having a hole in the van you can't
2:50 -really drive around like that it's just
2:51 -like an open invitation to a thief to
2:52 -come in and
2:54 -come in and grab your tools you know if
2:56 -you've got any left after being broken
2:57 -into measuring up from measuring up from Damage
3:00 -this wage line
3:01 -let's go from this wage line just here
3:04 -because that's the same on the new and
3:05 -the older vans that damage
3:07 -well
3:08 -the cut is up to about
3:10 -140 550 mil but there's also a bit of
3:14 -bending that dips down a bit a bit
3:16 -further and there there so
3:18 -really the damage is like
3:21 -we'd want to cover up to 130 mil from
3:23 -that swage
3:25 -let's have a look here Shield
3:30 -of that same go to the we'll go with
3:32 -that middle swage line
3:33 -here
3:34 -so 130 yeah so our our big shield is
3:38 -going to cover that nicely that's that's
3:40 -where we want it to go and we go an
3:42 -extra 10 mil over the top of that the
3:44 -cut is up for around about here and
3:46 -that's our standard shield so
3:48 -you know they've just gone so much lower
3:49 -on this one you know so much more
3:51 -aggressive
3:54 -so before we can get
3:56 -before we can really get too much done
3:57 -in here we're gonna have to
4:00 -you know we're gonna have to cut away
4:02 -all this excess so yeah
4:04 -dan is removing that latch out there so
4:06 -we've got a bit of room to get in there
4:07 -and work
4:08 -and
4:10 -and cut and saw all this excess away and
4:12 -then we can get about fit in our shield
4:15 -you can see some damage there
4:18 -where they've gone on it okay so here we Final fit
4:20 -are the leg work's been done for this
4:21 -we're just doing that just just doing
4:23 -the final fit now so we've been through
4:25 -the process we have cut away all that
4:27 -damage from the breaking or that jagged
4:29 -metal that was sticking out that which
4:31 -would have stopped this shield from
4:32 -sitting flush because it was bulging out
4:34 -from the door we've cleaned away all of
4:37 -that debris taken away that jagged metal
4:40 -we've marked up using a gasket as a
4:42 -template for the holes for for drilling
4:44 -for these stud positions we've blown
4:46 -away all the um debris everything that
4:48 -was sort of sitting around the area
4:50 -anything that's sitting on the body work
4:51 -all these little shavings of metal which
4:53 -could later on turn into rust we've rust
4:55 -protected the bare metal where we've cut
4:58 -and drilled the holes where we've cut
4:59 -out the jagged edges we've used wax all
5:02 -to give rust protection to the bare
5:04 -metal and now we're ready to do the
5:06 -final fix okay so we're done
5:10 -lock
5:12 -double lock
5:14 -check the door handle
5:17 -unlock
5:20 -and it opens
5:21 -the damage
5:22 -has been covered up Summary
5:24 -it's not a brand new door but it is a
5:26 -good quick effective solution got this
5:29 -vehicle back on the road and it's off to
5:30 -go to work
5:32 -there's also a shield there someone's
5:34 -going to break in again then
5:36 -trouble is you take these to a body shop
5:37 -repair you might have another hole in
5:39 -the door um you know just a few days
5:41 -later or a few weeks later typically we
5:44 -would use a smaller repair shield than
5:45 -this but this is our oversized solution
5:48 -so if you've got damage to your ford
5:50 -transit custom that's bigger than a
5:51 -regular size shield will fit that will
5:54 -cover over and you need to get your van
5:55 -back on the road this is a solution go
5:57 -to our website it's
6:00 -www.sussexinstallations.com of course i
6:02 -would suggest that you also get other
6:03 -security products fitted as well such as
6:06 -at least a shield to go inside the door
6:09 -to give some some more reinforcements
6:12 -against attack of your van and then
6:14 -shield for like the barn doors etc to go
6:17 -at the oh to go at the back
6:19 -and then of course we've got our
6:20 -deadlocks platinum packages and lots of
6:23 -other stuff on the website too so if you
6:25 -go to our website
6:26 -www.sussexinstallations.com
6:29 -putting the registration into our search
6:31 -bar we'll bring up security
6:33 -recommendations that we would recommend
6:35 -for your vehicle or just go to the
6:36 -contacts page fill out the contact us
6:38 -form and we'll give you advice depending
6:40 -on what your needs are
6:41 -hope you enjoyed this video don't forget
6:43 -to subscribe to the channel give us a
6:44 -like if you can and yeah keeping in
6:47 -touch with what's going on in van
6:48 -security with us here at sussex
6:50 -installations thanks for watching
7:04 -you

Transcript source: the YouTube transcript supplied for this project with minor corrections. Automated transcripts can contain recognition errors and should be checked against the original video.

Page details

Author
Jeff Scott
Publisher
Sussex Installation Team Ltd
Updated
2026-08-27
Primary focus
Attacks, shielding and repair
Jeff Scott, founder of Sussex Installation Team Ltd
About the author

Jeff Scott — Van Security Specialist and Industry Educator

Jeff Scott is the founder of Sussex Installation Team Ltd (Sussex Installations). He has fitted vehicle-security systems since 1997, started Sussex Installations in 2003 and has specialised in van security since 2008. His work combines installation, vulnerability research, product design, UK manufacturing and long-term public education.

In 2009, Jeff published the first known YouTube video explaining mechanical key-operated van deadlocks. He has continued documenting van-security products, installation standards, vehicle vulnerabilities and changing attack methods ever since – earning his description as "The OG Van Security YouTuber."

Jeff has supported thousands of professional vehicle aftermarket technicians across the UK and beyond with access to technical information, while actively promoting higher quality installation standards through his trade community ifitstuff.com since 2006.