OK, better this morning & only worked until it got up to 95, then called it quits. Here's the skinning stuff. Passenger side skin in place from yesterday.
I added a lower part below the AC box, because the roof panel would have been 122", needing two splices. Figured it was easier to just place the bottom panel first, then seam the roof at the top in one spot I could control.
Here's the groove for the 1/8" X 4" backer for the splice in the roof panel. Just used a router & plowed a slot for it to sit in. It's milled into the vent area as that's just where it was easiest to set things up. The roof panel is about 1/2" too narrow to fit at the edges (60 1/2" wide build because the frame is 1/2" too wide). The 60" aluminum won't cover completely either, but I'm not too worried about it. If I have a 1/4" gap at each edge, the aluminum molding will cover the edges with plenty of overlap to spare & the mastic will seal the edge as well.
Full panel in place showing the AC box. I've figured out how I'll mount the AC, let it slide & close for a weatherproof fit. Not time to explain it yet, so I'll wait until I have some pictures showing how it will install be made waterproof.
The hatch spar in place & the top skin glued with a few clamps to hold it until the glue sets up around the staples.
I'm going to slop on some urethane seal up the skins & keep water out of the joints prior to the aluminum skin being applied. An early end to the day today (only 6 hours). Next on the list will be the hatch build. I have most of the stuff to do it & get it made (struts, wiring, latch, ribs cut, etc.), but I'm thinking I'll work on it next weekend. Still need to do a couple more sketches & firm things up in my mind before I start. Making progress! As always, thanks for looking!