Box and Hole
My next question was simple. Where am I going to get my aluminum from? I haven't ordered any alclad yet, and didn't want to use something from the hardware store since it wasn't alclad. When I gutted the trailer, I had to tear out the bathroom stall since it wouldn't fit out the door, and because I planned to redo the bathroom anyhow. I grabbed the electric Milwaukee shears, and went to town getting a nice chunk of aluminum.
Mangled Bath StallI applied a liberal amount of paint stripper on the piece, cleaned the paint residue off with MEK, and cut it to fit the hole. I wasn't going for anything fancy (No Missouri shapes, no stars, no pointing fingers).
After laying out and drilling the holes, I used clecos to hold it in place temporarily while I drilled holes in the exterior panel. I then took the clecos out, laid a liberal bead of Sikaflex around the exterior of the new patch, and riveted the patch in place with Olympic rivets. It was only holding a patch in place, and I figured no need to use buck rivets. I let the sikaflex cure overnight and went outside this morning to wipe off the excess with MEK. All I need now is a rivet shaver and to install the plug.
Lots of sealant
Ready for the plug and rivet shaver.