I've been feeling guilty about leaving this thread unfinished, so here's the end. The new aluminum inner shell was templated from the original pieces. I used the old panels for the new belly pan.
At that point, I towed the trailer to my shop and started on the interior. Lots of wiring , plumbing and building cabinets to fit all those pesky curves!
Cork flooring, solar panel and professional upholstery and we were ready to go to the Vintage rally in Wenatchee.
Of course there is always more....a Zip-Dee to come and polish, polish, polish but it turned into a very comfortable trailer and it was a fun and challenging project.
Thanks for this forum and all the great info and support!