Thanks for the information. I appreciate it.
As for the metal interior, there are ways to reduce the sound aspects but not everything will be metal anyway, I will just use metal for the major framing of the cabinets and so on. Then you can add curtains, soft furniture and other things to reduce echo effect. Airstream has been doing this for years so I am not worried. I suppose I could use some sort of interior wood panelling if it was going to be a problem.
As for the butyl tape, I have used that to repair windows before so that is a good thought. Cover the outer studs with the tape and then rivet right through the tape. I will check out the other methods of insulating the walls.
As for the 3" spray in foam, that should provide good wall insulation in other areas leaving only a thermal bridge problem to solve.
Also I have been debating riveting techniques. Blind rivets are easier to work with in tubular aluminum but they could potentially allow water into the tube through the center of the rivet, unless I melt them or something.
I am making plans to build a truck camper from scratch using aluminum tube for the frame and then aluminum inside and outside for the skin. There are a number of reasons I want to go with aluminum including low weight. I like the look of it, and it is durable, being rot and corrosion free. Also since i have the skills to mig weld aluminum properly, why not. :) I even plan to make the framing for the cabinetry and so on out of aluminum for style as well as functionality.
I am in the planning phase, playing with my cad system and there is really only a couple of issues that i havent worked out.
I was interested in riveting on the skin airstream style using aircraft grade sheet aluminum but then I would have a nasty thermal bridge that would defeat my 3" of spray in foam insulation. So I was wondering if there would be something i could do to interfere with the bridge. Is there some sort of tape or so on that would allow the aluminum skin and studs to never directly touch? Also could I coat the rivets in something to break the thermal bridge? Any ideas?
Also I am concerned about water proofing. What kinds of sealers should i use between overlapping pieces of aluminum? Any suggestions?
Oh and while i have you aluminum experts on the line, if I choose to go with a polish coat, is there any kinds of sealers or other coatings i can put on the outside to have it keep its shine? I very well might have the camper painted but i figured I would ask.
I had been debating acquiring a vintage avion and restoring the trailer but when I started thinking about it I thought that I could almost build a replica of the trailer in honor of it for the amount of cash I would put into the restoration. Furthermore, even with restoration there is no guarantee that the camper wouldnt have frame damage or cracking that I couldnt see. Instead I was considering if I should just build the replica from scratch but I was wondering if anyone knew where i can get the plans to the old trailer.
Thanks in advance.