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 Topic: Camper Rebuild - Aluminium Advice
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29/6/2017 at 6:35pm
Location: Weymouth
Outfit: Bailey Pageant S7 Bretagne
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Hi,
I'm looking for some advice about aluminium skin. The plan I have is to basically replace everything in my 1979 Advantura camper except the existing floor - all the corners are rotten, the roof was repaired but in a kind of what-have-I-got-in-my-off-cuts-box kind of way (thought it is water-tight); and I want to change the layout enough that filling in things like the gas bottle door, various grills and repairing miscellaneous damage means I think it's easier to start almost from scratch.
In my experience, aluminium panels of this era are often joined with a grooved flat lock seam. This looks a bit complicated to me - and I'm assuming the are better adhesives now than in 1979, and so I'm thinking to use a countersunk lap seam (if I sound like I know what I'm talking about, it's only because I read this!) which will fit into a routed channel in a horizontal beam. The lap will "face up" and the sheet above it will just be bonded flat onto the lap, and a trim strip of some sort over the top to hide the seam.
So, some questions:
1) What thickness of aluminium sheet is about right for something like this? I'm guessing 1mm is about right, but I've struggled to find anything definitive.
2) Any suggestions on how wide the lap joint should be? I'm thinking about 10-15mm, but again: no experience here.
3) The Advantura has a kind of stepped aluminium profile (SF10?) - I'd like to replace that with smooth sheet. Is there any reason I shouldn't?
4) What adhesive(s) would anyone recommend for the interior panels and the aluminium? Something with good 'grab', I imagine - I'll be using pre-covered wallboard so I won't want to use any pins, staples, etc.
5) I'll need to remove the aluminium strips on the corners and won't really want to put them back until everything is done. What is a good, waterproof tape can I put around the corners to keep the rain out in the mean time?
Any and all advice much appreciated.
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