Hello from Colorado: I've installed new belly pans on 5 Airstreams over the years. God help me. It is a hard job for me. I too buy my aluminum 5052 at .025 thick from Airparts in Kansas City. I have done all five trailers side to side, or east west as it were. I allow plenty of width to tuck under the body side wraps by several inches. Here is a couple of photos of the work in progress. I insulated with rigid foam insulation, I used a floor jack with a piece of plywood to hold the aluminum in place while I drilled and riveted it in place. I used a round "cow magnet" to locate the steel cross members for drilling, and I finally got done with the job.
David
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WBCCI #8607 VAC Region 11
KnowledgeBase trailer renovation threads: 69 Globetrotter, 76 Sovereign, 75 Overlander, 66 Trade Wind Such fun !
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