Great feedback, thx. I agree 100% about weight up high & being as light as possible. Admittedly, before I bought the tonneau cover I had actually thought it was lighter. While it is probably not as strong as carbon fiber it is already formed, shaped, painted, gel coated & good to go now. It also has built in water flow with perfect over hang edges.
And... while I want it to be solid & quality, this is a budget build & this saved me a ton of time & cost me a whopping $200 WITH struts, seals folding & lock/locking mechanisms. (New they are $1,950 with tax & the mechanism works for a wedge build.) Seriously, the only down side seems that it is a tad heavier than I'd hoped...and I wouldn't have minded it another 1-2' in length but nearly 8.5' is pretty good & over 6 wide is great.
As to the rest of the build, I have a Bed-Rug with my current color matched Leer shell. (I will likely sell this shell. I am still debating on many things though & in planning stages. I just thought I'd plan it around this roof piece & go from there.
Regarding the sides, I'm considering composite sides with a basic aluminum frame or 80/20 with the same or foam with aluminum edging (foamie?). I also have considered aluminum frame, AL checkerplate sides or AL siding with foam insulation & FRP inner sides. I want it less than <550# for the entire shell itself so have to really watch it if this is my roof choice.
As far as the inner build I want it basic & modular with a slide out camp kitchen on one side. I am going to splurge on Maxx air fan, solar, a 2nd battery (a LiFePO) since the truck already has a OEM place for it in the engine bay. I already have 2 induction single cook tops & prefer to be all electric since I'm going solar but am still debating on heat options. I prefer to avoid propane entirely unless I go with a portable inline hot water heater which I doubt. I would love ambulance doors but may stay with a large lift maintaining the tailgate for simplicity. (Watching for one of those commercial contractor shells to cannibalize the doors.
I love the rig the Ambition Strikes YouTube channel couple made...but their goals, budget & donor truck were 100% different from mine but really liked many of their techniques. I have many tools but this is a DIY project & I don't weld (I can braze aluminum the way DualEx did) nor do I have a CNC machine. More than you probably wanted & should post here if I don't want to fully derail this thread...I should probably start a new one. ?