Suggestion for the roof, f you check on Sabconsulting, he did an aluminum roof on his truck camper. Maybe you could weld come “blades” underneath the roof material, that “slide in/mate to catches attached to the plywood. My German bags have this type of connection on the racks on my motorcycle. I could see something like this working for you. So when you slide on the roof, it tightens as it is slides into these multiple blade locations and you leave a 2” or 3” tab along the back end, that is then bent down over the back edge of the roof and bolts into the structure at the rear. You could have tabs pre bent over the outside and front edges to allow bolting in place, after the blades are mated. I would not put any bolts or holes on the front edge to eliminate any “weeping” opportunities for leaking.
Have you considered placing “ears” welded to the roof to allow future placements for Solar Panels? Wire and combiner box can be installed at rear side to eliminate installation on the roof, as well as ears or conduit welded to the roof to allow cable passageways. I would also install a rack/or channel to allow future use. To keep to your slick roof plan, you could use the channel material that is now used on sport trucks, like an aluminum unistrut.
Clicky b
