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Old 03-05-2010, 04:56 PM   #1
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1969 27' Overlander
Los Angeles , California
Join Date: Mar 2010
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tips on skinning with aluminum?

I'm renovating a '69 Overlander for a friend. The trailer was already completely gutted down to the frame. She would like me to skin the ends in aluminum. Are there templates for cutting the necessary shapes required to get the sheet metal to form the proper curves when riveted together? There are no ribs whatsoever in the curved areas, but I've seen other examples of this look. Do I need to install some framing, or is it enough to get the metal to form the proper shape and attach it at the windows and the first rib as one heads toward the interior? I'm totally stumped.

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Old 03-05-2010, 05:10 PM   #2
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1956 22' Safari
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Conifer/Evergreen , Colorado
Join Date: Feb 2002
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By 1969 the end caps were a plastic (or fiberglass) formed shaped segments - that's why there are no support ribs. They spanned the width and were attached at the rib and window frames. The exterior caps are also constructed out of shaped (stretch formed) sheets - they aren't flat, so using flat aluminum to make the inside curves is tough. The older (pre-1958) 13 panel end caps were flat segments that are riveted together...those are most likely the interior segments that you've seen.

Some folks have overlayed aluminum sheets (the more segments the better) to get the "look" of the older trailers but I don't think there are segment patterns available. Besides, every trailer is a little different anyways...can it be done, yes...but it's not easy figuring it out - kinda trial & error. I would say making templates out of thin cardboard would be the way to go ~

Good luck!

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