Progress has been slow - despite the many hours I've logged on this project. Of course, a lot of that time was spent just looking & thinking (some might say daydreaming).
Anyway, after deciding that the roof needed some additional help for supporting the factory original A/C I built up a mildly engineered support from 3/8" plywood and poplar.
I plan to insulate the walls with 3/8" closed cell foam, so it will butt up flush with the ply. The thing is glued in place with PL Premium polyurethane glue (I took my cue from Kevin61 's Boler
rebuild videos - thanks Kevin). I also used four stainless steel screws with fender washers placed through the roof and mounted with threaded inserts in the plywood. I plan to brush a coat of epoxy over the screw heads on the exterior of the roof as an added precaution against leaks
I'm pleased by how much rigidity it adds to the roof. But of course, the real test will take place when I start towing the finished product down the road with that AC mounted up there. Maybe I'll add a little glass cloth to the contraption. Any thoughts on this?
The first pic also shows the front window I'm glassing over. I've been alternating between exterior & interior work. The most time consuming exterior job thus far was removal of silicone caulk from the belly band - what a chore!