10 months and hundreds of man-hours later...

[Brettski]

Sprayable 3M contact cement to stick the aluminum to the sides and roof.



Once contact cement touches, there ain't no moving it. Se we rigged up a way to spray the panel and the aluminum, then lower the aluminum down as we got it all aligned. Happy to report it went on straight!




This last pic was later after having already routed out the aluminum for the door/window. Man the router on aluminum is messy! Hot aluminum sharps flying everywhere. Good times.

 

[Brettski]

So the interior was designed to have shallow cabinets and shelves on the front wall. In this pic below you can see two large-ish cabinets. Between them is an open column that goes down to the "basement". The wiring panel is in the top center cabinet and the column has enough space for air ducting if we add a furnace. Don't think we'll need it given the 1" insulation and wall thickness. The cubbies at top left and right were designed to hold knick nacks, water bottles, etc with about about 4" high rail to keep things from falling out.

You can make out a flip door to the "basement". We've got 3 doors on piano hinges to access this space. Water tank is in there and so will the pump and hose. We're putting an access panel on the passenger side to easily get to powered water supply. Will take a few more pics of this later.


Out the back is the big gear drawer. 4ft x 4ft and 9" deep it is on 450# sliders and is fully extendable. I built something like this in my Landscruiser and it's awesome. Particularly for keeping camping gear and stuff accessible but out of the way.

MaxFan in the roof too.

 

[Titanpat57]

Way to grab it and growl!

 

[Brettski]

Here's a better look at the "basement". This area sits in front of the pull out drawer and was designed to house the water tank and heater (if we add one) plus provide out of the way storage for less used items.

3 doors access it, one is the full width, the other two open up gull wing style.

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[lifenajeep]

Great idea with the 1" foam and spray adhesive