Thought over the roof rebuild for a while and realized it would be easier and best to just rebuild the roof from scratch. I took couple measurements and started removing the old roof. There's quite a few posts here on how to remove a heco lift system such as this one: https://www.wanderth...n-bars-summary/
After a friend and I got the roof off i just cut it up with a reciprocating saw and took it to the dump. The roof is just 3/4" styrofoam with 1x3s around the perimeter 2 1x3s running left to right and aluminum skins on the top and bottom.
For the new roof the frame around the perimeter will be 3/4" plywood spliced together to make it 11' long with 2-3 1" aluminum square tube cross members and 1" XPS 25psi compression strength foam between. Then I'll glass both sides, the top will be 2 layers of 6oz glass, inside will be 1 layer of 6oz glass all laminated with marine epoxy. I make surfboards for fun so I figured this should be the easiest and best construction. Maybe not the cheapest though...
Once I had the roof off I decided it would be the right time to rebuild the bed overhang since the heco gears would need to be removed to do so. The OSB they used was so rotten and so well adhered to the aluminum skin that it was impossible to get off. After a few hours of scraping with a heat gun solvents I decided it would be easier to also glass this too and toss out the old aluminum skin.
More to come on the roof and the bed.