We’re very slowly doing the same things! I’d love to see yours and what you do to it! I’m hoping to find some more time this year and maybe finish ours up enough to use it!
1. Plywood Floor. We replaced it all using 2 sheets of 3/4” marine grade plywood. The plywood actually provides a lot of floor structure, so I wouldn’t recommend patching it like I see a lot of people talk about here. It’s not super hard, but a lot of work. Originally it would be held in place with a
fiberglass “tab” or “L” that went along the sides. That has to be removed so the old can come out and new can go in. We took ours out with an angle grinder and lot of patience. Then we reinstalled with some
fiberglass mesh and resin. I also gave a good coat of fiberglass resin to the plywood itself to seal it more.
2.
Windows. We pulled ours out and resealed to the frame... but, we need to redo the same plastic rubber seals in the front and back, as well as the plexiglass. Keep me posted if you find a dealer of that seal please!
3. Cabinets. None of the cabinets or closet provide any support to the shell. But the shell does support all of the upper cabinets. There will be wood strips that are adhered to the fiberglass. The upper cabinets screw into those strips to stay up. Our strips were coming away from the shell. We replaced them with new plywood strips with high strength epoxy. (Fiberglassing in them probably would be even better.). We added the same strips for the seating area for better support of the seats.
4. Wall Covering. The wall covering was the hardest for us to decide what to do! We also wanted a easy to clean vinyl but knew there wasn’t a way in heck we would be able to tackle those rounded corners and were about to take it to an upholstery shop. The forums speak a lot of “rat fur” which I finally came to realize is hull liner. I ordered one that is fuzzy but short nap and it is stretchy enough that the corners weren’t too bad. We ran all our
electrical lines (new) by making shallow slits in the insulation first. Then installed the hull liner with 3M super 77 spray adhesive. It all not perfect, but the cabinets will hide my imperfect spots in the corners.
One other thing to consider is adding a bit of support under the frame in the front and back so it extends to the corners, (by the door and back seating areas). Ours was sagging a bit. It made the door so it was out of alignment. The new plywood bottom helped for some time, but eventually must have bowed with the sag. A little bit of metal tube added to our frame and we were back to level.