from experience if you want to go diy ,make your frame from steel the drawers from aluminum and cover everything with russian plywood,it will be the most cost effective ,check overland bound drawer build on youtube .
https://expeditionportal.com/forum/threads/land-rover-ideas-for-jeeps.218029/post-2842898
i say you need to compleet it ,the fender flares they need to match and the roof is doable check the like above.
I do not about aerospace standards,i will check the ipc-620 tomorrow at work and will report back remember there is class 1/2/3 ,nothing is flying or going into space and it is not medical so it class 1.
Wicking is accepted ,the maximum is 2 diameter of the wire, so it goes under the rubber and makes a solide mechanical fixture so if the wires vibrates it won’t brake the wire
You need a gap for when everything flex ,and you just said it was in an accident maybe it was not repaired to spec.
What you can do is to paint the gap in black so it work as a transition.
For the sunrof you are saying there is a gap between the the roof and the the assembly of the sunroof ?
Maybe someone walked on the roof and bent it .
Usualy sunroof leaks ar from the drain hose that can get disconnected or a crack in the drain where it connects to the hose
One another area to...