Questions for the aluminum crowd

[Aint2Proud]

I am planning on doing an aluminum skinned Diner profile. I am one of those who needs to think things through before I start cutting. I cannot wrap my head around a couple of things:
1) How do you cut the sides for the hatch with aluminum? According to Steve's manual it seems like you would need to cover a couple of small areas with AL and trim. I was wondering how others have done it.
2) How do you terminate the roof sheet of aluminum at the hurricane hinge?
3) If I do a flush mount door with a piano hinge how do I do the trim pieces where the hinge is attached? Do you do anything special to the trim joint where it meets itself after going around the entire door or door opening?
4) I have read that aluminum can expand up to an 1/8 of an inch or so. How does this affect the way you cut it to profile? Do you allow for expansion or cut it to the exact profile of your wall and call it good? I am especially curious on this point as it relates to the roof where you will have screws through it on each side every few inches.

Also I have not seen too many gatherings or meetups in NC. Is there anyone around Raleigh? Thanks in advance!

Ryan

[Ageless]

.000023 per degree Celsius, a 1 meter bar will grow 2.3 mm if its temperture increases 100 degrees C.