by piperpilot3tk » Sun Dec 22, 2013 10:16 pm
The interior wall plywood is only required if you have wall studs made Z angle and are not made from tubing. I have Z angle wall studs and after reinforcing the frame with real cross members made out of tubing, my walls do not flex. All 230 pounds of me was on my roof today with no ply on the interior Z angle wall studs,and no wall flex. Plywood will make the walls much stiffer, especially if you are creating a bending load by attaching something to the interior of the wall such as bunk beds or shelves.
The use of steel wall skins versus aluminum will not add any measurable strength, unless the steel is thicker than the aluminum. It is relatively inexpensive to spec a new trailer with .030" skins instead of the standard .024". Any way you look at it the walls in a standard cargo trailer are not meant to be primary load bearing members. You are always supposed to secure the cargo or load to the floor, the walls and roof are just there as an enclosure, although a sturdy one. There are exceptions with trailers that are built with heavy wall structure, but if the frame and cross members are heavy enough then the walls will not flex when driving over rugged terrain, nor will they flex if loads imparted on them during your conversion is designed to be primarily in compression (load running down the studs, and not twisting or side loading the wall).