Teardrops n Tiny Travel Trailers

I'm wanting to install a couple of big windows in my new trailer. I think they are 20 or 24" high and 4' long. I'll need to cut out some of the frame work to do so. Being I can't weld aluminum I've been thinking on how to rebuild the supports.

I think there may be a place by me that can weld aluminum but I do worry that it could cause skin issues being our skin is bonded with some sort of adhesive (not VHB tape).

Another thing I've thought about doing is just bonding in more aluminum tubing with VHB and putting in some angle in the corners where the tubing meets at a 90* angle.

Or ripping down some poplar and boding that with some PL construction adhesive.

I really want to avoid using steel to keep away from dissimilar metal corrosion issues. But I could also weld up a steel frame and bond that in.

Any suggestions?

I'm not a professional aluminum welder, but if you are going to go that route, and are concerned about heat transfer, I'd look for someplace with an aluminum MIG setup. TIG is precise, and lovely to look at, but it is slow, and really heats up the surrounding aluminum. A lot can be done with proper heatsinks, and MIG is fast. Most aluminum boat shops should be able to do this. Another option would be to bolt together a aluminum frame, and not worry too much about the dissimilar metals problem. Every jet we fly on has 10,000 steel bolts and brackets in the wings, all attached to the aluminum spars and ribs. It can cause corrosion, but there are a myriad of products out there that will help. Boshield, or corrosion-x are a couple options. Zinc chromate primer will help also. It used to be available in rattle cans, but wear a respirator, or you'll grow a third head . Good luck, sounds like fun! Kyle

Your right on the corrosion part. I have some 1" steel tubing I could use I may go that route.

I've shot plenty of zinc chromate, along with swimming in MEK & jet fuel, and playing with alodine working on aircraft.