I posted a picture of the finished front end cap on the "what did you get for your trailer today" thread. I received a few inquires on how to complete this, so thought I would start a thread.
I got this idea from a post from Zeppelinium, that he posted a while back. Zeppelinium was nice enough to send me his templates but I had already came up with my own by the time I got his. I guess I am impatient! I can not take credit for coming up with this on my own because without Zeppelinium post I probably would of never tackled this.
While the end result is similar we used a different approach.
Material used .032 5052
(10) 11.5" X 51"
(1) 11" X 51" center piece
The first step is to remove the front plastic end cap. Remove all the insulation and seal all the lights, AIRSTEAM letters, rocksheild rivets.... from the inside. The pinkish purple blocks shown in the picture is 1.75" styrofoam insulation board that is cut into small blocks and glued to the outer skin with construction adhesive. This is put in place so you keep the same spacing between the wall and have something to push the aluminum segments against.
The next step is to reinsulate between the styrofoam blocks.
now you are ready to hang the first piece of aluminum and then start working your way towards the center.
No complex curves were cut, the aluminum was hung per the sizes listed above. The aluminum was overlapped and it creates the desired curves.
Cleco's rivet tools is a must and I used Olyimpia shaveable rivets to give it the buck rivet look.
Here is a picture of the front completed without the curtain and valance.
Hope this helps, I am going to start on the rear tomorrow since I get Easter Monday off work. Didn't take many pictures in the front because really was not planning on posting this. I will post pictures of the rear showing the progress tomorrow.
Wish me Luck!