First off, drilling out bucked rivets and replacing a panel is not as bad as you would think...it's actually a fun project. We have replaced several panels
on a couple of different trailers. There is butyl tape or some other kind of "glue/sealant" that is between the panel seams - this seal needs to be broken, but can be done with a large knife slid between the panels. Then you use the existing panel as a template to drill the holes for the new rivets...(see my link above for step-by-step & pics).
Getting new aluminum the right size isn't a problem either...but it won't be painted beige like your Argosy - it will be raw aluminum or panted white. We purchased our 2024-T3 aluminum online at Airparts, Inc.
We ordered a 30+ foot long piece because we were replacing several panels on three different trailers. They sell it by the foot...
Is the interior stripped or still "in place"? If you plan on bucking rivets for the new roof panel, the interior panels will have to be removed to access the backside. Otherwise you can use Olympic Rivets and leave the interior in place. If you are going to do that many Olympic rivets, you will definately want to purchase a rivet shaver.
But, this is on an Argosy, right? If you try stripping the roof with Aircraft Stripper it would be pretty impossible to not get stripper on the painted sides of the trailer. Are you planning on stripping and polishing/painting the whole trailer? If you replace the roof section - it would be aluminum - not painted to match the rest of the trailer...and the Argosy end caps are not aluminum so they have to be painted something
. I have seen a couple of polished Argosys, but they have the end caps painted - sometimes a color sometimes "silver". It actually looks okay...
Are you crazy? Not sure...that's for you
to decide. I wouldn't hesitate doing it on a trailer that was undergoing a complete
restoration...but there is a little more to consider with a painted Argosy that's in good shape otherwise. Hope these points help you think through the process. Good luck with whatever you decide to do.