Thanks for the nice details. I was wondering how you install the window and the door to cover it. How do you trim it to prevent leaking. I have been looking for alumimun extrusions to use but I have not found any.
The place I used for my aluminum extrusions was speedymetals.com and my sheeting was from a local sheet metal shop.
You will have to figure how thick your plywood/aluminum/frp 'sandwich' will be to determine the channel dimensions for your aluminum. I think I explained this process a littler earlier in the thread. I don't have time to go through it right now. Pretty busy right now.
the window was mounted with it's own flange with the flange on the inside of the trailer. The awning window was mounted with a piano hinge on the top with gas shocks mounted to the inside window jam and on the awning. This has worked very good so far and I have had 0 issues as of yet. I do around 14 events annually and have been in rain and wind as well and everything works good. As far as leaking, you'lll want to use high grade 100% silicone and use it liberally but neatly. Put it in the channel before you slide the channel over your 'sandwich' and also use it on all seams and edges where water could penetrate. If you have an unsteady hand and cant get good even caulk lines use masking tape where you want a nice cosmetic appearance.