Yea. I'm trying to avoid filon because of my current delam problems. The OEM front cap from Keystone is less than $500 plus shipping plus the pain to install it. However, I don't want to have the same issues in a couple of years because its a pain to replace.
I think that I could use a substructure of luan in the flat areas but I have a curve at the top and bottom of the camper. So, I'm thinking that in those areas, I can make curved 1/2" plywood pieces to place on 16" centers. I can make a template from a piece of cardboard and cut all plywood to match the template. I will install the substructure first. After using the existing front cap as a template to cut the new fiberglass, I will glue the new fiberglass to the substructure clamping the fiberglass on at the top and bottom. It will take some time and add a little weight but I think that it will be worth it in the end.
Thoughts?
