kreativekvs209, how are you going to construct the wall where the back door will go? Could you explain your reference to ‘metal rods’ ? What kind and size of door will you get? I might go with a steel plain slab ext door in a 2×4 wall.

It looks like you are framing out a 2×4 wall over the top of the existing aluminum one which will reduce overall width. Why not just go with plywood onto of the original aluminum studs?

Also, do you have a rear bumper?

I’m using 1 1/4” studs for the frame. I’m only framing up this side, because I’m having my hand washing sink close to the rear next to the serving window. while my 3 bay sink will be towards the front of  the same wall, and since I’m not sure exactly how I want to make my service table. I’m going to create some space between the outside wall and the inside wall for running all the plumbing I need for the hand wash sink’s hot/cold water pipes and the drainage plumbing. I’ve talked to the inspectors and they said that if it’s in the walls then I don’t have to worry about all the regulations to make all the pipes ” easily cleanable “…. honestly all the framing wood and hardware costed me about $20. which is not much to cancel out all of the headache. but the other side I will be just boarding up to the truck’s metal frame. ( after I run all the electrical lines )

 

for the back door, I’m going to be using square metal tubes to build the frame for the walls and the frame for the door. which will be a massive door. just in case I decide to add or subtract major appliances. then insulate with left over insulations ( insulation isn’t too important for me since I’m here in central California which seldom gets below 0 ) then covered with plyboard then frp. on the inside. then I’m using the leftover sheet metal which I’ve taken off of the cargo area walls, for the outside.. ( or I may just buy new sheet metal for the outside depending on funds at the time of doing.

 

and yes I do have a nice and sturdy rear bumper.  if your thinking about where I’m going to be posting  my genny, just know that I will be framing up  a box for it on the front driver side bumper so it will be as far away from my service window as possible. and I’m placing my breaker box directly behind the driver seat.

 

I have acouple of “paying” projects coming up which will fund my back wall and door. so hopefully with-in a couple of weeks I should have pictures up.