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Dave
Tyvek will pass moisture, not quickly, but it is pervious. Brett's idea of sealing all edges is good, I did that on my floor. Think seriously about some type of thermal break between the wood and aluminum, I believe you will have more trouble from the conductivity of the aluminum than leaks within the walls. On cool damp days I could see lines of moisture from the ribs on my inner skin. To me that meant that wood against the aluminum was going to be like a sponge.
The foam did stiffen the body a lot, even helped a little with sound. It is easy to fix, a sharp knife and a putty knife and you can pop a piece right out to do a repair. Fill the hole with some from a spray can and you never know it was done.
Another thing besides leaks and water in the walls I would think about early on is the loss of strength to the shell by removing the inner skin and how you can compensate for that. It is like peeling the paper off one side of a piece of cardboard when you remove the inner skin.
If you are planning on using paneling my experience says you are going have to form it before you install. There is a luan that is used for making curves that would work. I like the idea of that and veneer if I can find an adhesive that would hold, maybe one of the polyurethanes. Research time.
John
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