Replacement exterior panels?

[deke]

We have a (new to us) 85 Dutchmen 801 Duck that we're refurbishing. When I inspected it during purchase I noticed some of the top trim was loose and pulling away (2nd pic). I figured I'd be able to drive in some longer screws and recaulk.

Ha. I should have looked more carefully. It turns out the roof side panel is completely rotted on both ends. Pics show the exterior before pulling off the panel, the leaky corner, the panel after I removed it, the damage at the front, and the surface texture. The other end of the panel is similarly damaged, though not quite as bad.

I don't think I can repair the panel, so am looking to replace it. I'd love if I could find aluminum skin that matches the rest of the trailer, although my searches haven't turned up anything yet.

Barring that I was just going to make a new panel from plywood and paint it. Anyone have any thoughts or advice? "Inspect more thoroughly" has already been noted.

 

[chrisski]

Do you have access to a sheet metal brake?

If not, plywood would be the way to go. I don’t have access to a sheet metal brake. The body shop used one to manufacture a side panel for me when the manufacturer could not provide the part.

 

[deke]

Thanks. Unfortunately I do not. Since the panel is longer than 8ft my current plan is to make the panel out of two layers of 1/2 plywood so I can stagger the joints.

 

[Franktafl]

I would recommend doing a Google search for “RV SALVAGE YARDS”. You may get lucky and find another RV of your type.