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Old 08-30-2017, 02:17 PM   #15
Larryjb
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Join Date: Nov 2016
Location: Vancouver BC
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I don't think replaceable panels would give the required strength. I have found that the panels don't have studs, but get their strength from single sheets of aluminum permanently glued to Styrofoam.

I think the overall strength could be improved if the ends of each shell were made of a single piece of tubular aluminum. You may have to use 3 pieces (2 verticals for sides, 1 horizontal for the roof) welded together. The open sides of my upper shells are quite floppy. One shell is actually bowing out quite a bit. I'll post pictures later in a separate thread.
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Larry

2002 Tahoe
2008 4.6 Explorer
2001 2720SD

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