How to install teardrop trailer aluminum skin?

In this blog post, we will answer the question: “How to install teardrop trailer aluminum skin?” We will discuss the steps for this project and the necessary equipment and tools. We will also talk about the benefits of using aluminum skin for teardrop trailers. At the end of this post, you should be able to install aluminum skin on your trailer in less than a day.

How to install teardrop trailer aluminum skin?

To install teardrop trailer aluminum skin, follow the steps described below.

  • Measure the trailer
  • Cut the aluminum sheets
  • Cut the doors and windows
  • Cut the doors, windows, and galley  
  • Install the side skin
  • Install the top skin

Measure the trailer

  • First, you need to get the dimensions of the teardrop trailer to install the aluminum skin. The aluminum skin is mostly installed on the outside of a teardrop trailer. Hence, you are required to take the outer measurements of the trailer.
  • Measure the sides of the trailer, including the length and width. Next, you need to measure the galley or the hatch area separately. Note down the length, width, and height. Be sure to measure the overall roof, front, and back part of the teardrop camper.
  • Note down the accurate measurements since you must purchase the aluminum sheets accordingly. The measurements are the most crucial part of the teardrop trailer.

Cut the aluminum sheets

  • Next, you will need to cut the aluminum sheets to start this project. This is an easy step, but purchase aluminum sheets that are a little bigger than the actual measurements. 
  • A teardrop trailer is round at the front and back, and it has an arch on top and on either side. You must purchase aluminum sheets a little bigger than the actual measurements.
  • It’s always good to start working on the sides of the trailer. Cut the sides of the aluminum sheets first based on the measurements. The easiest way is to hold the sheets against the sides of the camper and draw the shape of the sheets with a marker. 
  • You will require help from another person for this step or will be required to use fasteners to hold the sheets in place.
  • Be sure to get aluminum sheets that are thick enough to serve the purpose. Once you mark the sheets, you can take them down and start cutting them to the right shape. 
  • It is important to get the curvature of the teardrop trailer correctly. This is an important step, and you will need accuracy. For the top, you can use a long aluminum sheet based on the measurements.
  • Remember that the trailer has wheels, and you will need to mark the area for the wheels and cut the sheet accordingly.
  • If you are unable to cut the aluminum skin according to the measurements, you can always fix it and cut off the extras.

Cut the doors, windows, and galley  

  • You must cut the cavity for the doors and windows on the side of the trailer skin. Ensure that you cut out the aluminum sheet exactly as per the measurements of the teardrop trailer door. Do the same for the windows of the trailer on each side.
  • The alley or the hatch will need to be opened separately. Hence, you will need to cut a piece of aluminum sheet from the piece you plan to install on top. Make sure to get this piece separately since you must install it later.

Install the side skin

  • Start the installation process by fixing the sides of the trailer. Since you already have the aluminum sheet cut to the right shape, you can install it to the sides with the help of adhesive.
  • Be sure to sand the walls of the trailer and remove any bumps to ensure the surface is level.
  • Add enough adhesive and start fixing the sheets from one side. Work your way through and apply pressure on the sheet for the adhesive to hold. You will require extra hands to help you in this process. Hold the sheet firmly to the trailer’s surface for a while to make contact with the adhesive.
  • Make sure that the cavities for the doors and windows match the trailer. If you are unable to cut the aluminum skid as per the measurements of the trailer, you can simply add adhesive and fix the entire sheet to the side. Note that the extra parts of the sheet will be projected on top and on the sides.
  • Once you fix the sheets to the sides, you can run the cutter neatly along the borders to cut off the extra material. You can also cut out the area for the wheels by running the cutting machine along the borders.
  • Use screws or rivets that are specially made for aluminum and secure the aluminum to the trailer all the way through the border. Start from the bottom left side, work to the top, and finish at the right bottom.

Install the top skin

  • Once you have installed the side aluminum skin, you can move on to the next step and start installing the top.
  • Since the teardrop trailer has an egg shape, you will need to work part by part. Start with the front of the trailer by following the same process with adhesive.
  • If you are unable to work with a large aluminum sheet, you can cut the sheet into smaller parts and start fixing them accordingly. This is an easier process, but you might have small lines in between each sheet. Use screws or rivets and drill them into the roof of the trailer. Now, the trailer shell should be complete.

Fix the galley and door skin

  • The final step is to fix the aluminum skin for the galley and the door. This should be an easy task since you are done with the most difficult part. Follow the same process and make sure to keep space for the hinges. You might need to make a few adjustments and cut out small pieces from the door and galley for the hinges.
  • Follow the same sticking process, and you should be done with installing the teardrop trailer aluminum skid. Be sure to wear safety gear like gloves and glasses while working on this project, and feel free to get help from another person. Get in touch with an expert if you are unable to do this work on your own.

Benefits of teardrop trailer aluminum skin

There are various benefits of installing aluminum skin for a teardrop trailer. Here are some of the benefits described below.

They are rust-free

  • One of the major advantages of aluminum skin for teardrop trailers is that they are rust-free. Aluminum has rust-resistant properties, and no need to worry about water. They are also easy to clean, and there is not much maintenance compared to the other trailer skins.

They are lightweight

  • Since aluminum is lightweight, they are one of the best options for your teardrop trailer. Most campers prefer to have a light aluminum skin for their teardrop trailer. Compared to steel, they are way lighter and do not add much to the trailer’s dry weight.

Better lifespan

  • Steel is prone to rust, and fiberglass is prone to scratches, dents, and lamination. These components are not good for rain, and their lifespan is shorter when compared to aluminum.

Higher resale value

  • While this might not be important, it is still considered a benefit. Aluminum has better resale value and might just add to your trailer’s overall appearance and worth, even if you plan on selling it.


In this blog post, we have answered the question: “How to install teardrop trailer aluminum skin?” We discussed the steps for this project and the necessary equipment and tools. We have also talked about the benefits of using aluminum skin for teardrop trailers.


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