Blue Sky
You image attached to your posting brings up a question I have long pondered.
How large a portal cut in the side of the floorpak can one make without structural issues ?
The round hole is a very strong shape structuraly.
David Graves
Ah, that's the $13,000 question. Round is certainly better, but I cut a square hole to the rear of the wheel arch, staying an inch or more away from the edges of the plywood, boxed in from the outside, good for frying pans but probably too shallow for a battery, fine so far...
Round or oval is better. My sense is that these campers are pretty light, and the weight is distributed over the length of the bed (6.5 feet), so a hole the size of the ones used for the turnbuckle access are probably ok to add on each side, assuming you are not blasting down trails getting air. If the plywood were to fail, it would probably buckle inward along a line parallel to the floor at about the middle of the hole you cut. Fixable but something bad is probably going to happen elsewhere in the structure too.