Thanks for the advice. All of the photos showed up on my computer because I was signed in to DropBox, I guess.
I have more photos, if there's something in particular somebody would like to see please ask.
The dilemma here is that 1992 Itasca Spirit's ceiling/roof panels are only 1" thick total. And they are two pieces of 1/8" luan with foam between. That's it. two pieces of 5.5" plywood on either side of the AC hole, but they did NOT go from side to side, only in the middle. So nothing spanned the width of the roof.
I used Aluminum from 8020.net (think adult erector set)
my ceiling/roof panel ended up 1.25" thick and I used a corner molding with a deeper flange over the corner to make up for the extra bit.
West Systems G/flex 650 epoxy for everything. there is not one metal fastener in my roof holding things together. When I installed my new panel I hung from the AC hole with all my weight and it is much stronger.
Now, I do have a laundry list of things I've upgraded or modified on my RV. I'd be happy to list those things here too. Everything you can think of.
I'm finishing up the roof this week and will be putting my solar panel grid and wifi antenna back on in the next coming days.
This is a huge project, but very doable.
