Westend, thanks for the info, I will go over your build carefully. I plan to make some significant changes to the floor plan which will end up moving the shower and toilet (hence the black and grey water tanks), I'm doing this to open up the main living area more.
I am leaning towards the aluminum siding/roofing. I'm not sure how much I will be able to reuse since I will me moving a lot of the windows around. I will also be relocating the roof top A/C and also the roof vents, so I'm not sure how much of the roofing I will be able to reuse.
I plan to reuse the jalousie windows. I realize they are not as energy efficient as new sliders would be, but I like being able to open them for ventilation even if it's raining.
I am considering using spray in polyurethane insulation if I can find it for a reasonable cost. I also plan to do some kind of waterproofing/sealing of the exterior plywood.
Right now I am estimating a budget of around $5k and it sounds like I might be in the ballpark based on your numbers.
