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Looking at all the posts on rigidity I have to agree although no structural engineer I do have one tip the sheeting on the inside of vans is pretty thin Ply wood but does add a great deal to the wall. So where you are doing your work at the back you could beef this up a bit with some thicker ply screwed in place and this should add some strength.

Why not stick some pics up of the project as it gose so we can give suggestions as it happens

Andy

as almost everyone has said rigity lol i once done the same for a home made gocart :)

what i done was got some 2x1 and constructed a simple framework big enough to fit the cart through comfortably. then make another frame up that would fit inside the first one not a tight fit but comfortable one with say 2mm gap. take the first frame and attach to the inside of the caravan just under the window area(this way it stops the window shaking around should it be a windy day as you can screw the window down th the frame work).

take a drill bit that will allow an jigsaw blade/hacksaw blade to go through the caravan wall.

drill a hole in each of the 4 inside corners.

on the outside match the holes up with an straight edge

take said hacksaw(lots of sweat) or jigsaw (with metal cutting blade attached) and cut from one hole to the other untill you have a "gaping lion flap" size hole in the rear of the van.

take the 2nd framework and fix this to said flap screw from the outside to the framework on the inside.

now what i done was sealed all the way around the inside of the gap(between outside wall and inside wall with expandy foam allow it to go hard then any excess that may of squirted out cut it off with a knife

then got some heavy duty T hinges and attached them to the bottom edge of both frameworks so the flap drops down like a lil table and to help with loading/unloading.

also a dropdown leg or 2 attached to the outside of the flap just to take some of the preassure off the hinges if using it as an workbench could also attach an bench vice but this would make the flap even heavier :/

as for securing the flap when towing u screwed 2 eye bolts through the framework(on the inside) and 2 others through the floor in line with others on framework and attach some bungie cords to stop it falling down when you pull away lol

i did have the detail drawings somewhere(im a bit sad like that) so if i find them will scan them in and email them or message you them if want??

as for storage i used the exsisting cupboards for tools parts ect and to stop the tools ect departing the cupboards in transit just used a few cheap hasp nd staples(from toolstation) and a bolt throrugh to keep them closed

:)

good luck i hope this may be of some help for your idea's

kev....