I’m thinking of building the basic topper out of 2x4s then build the pop up sleeping area out of the aluminum. Do you see any problems with that idea?
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So are you planning on making the pop up sleeping area removable? Or is it always going to be attached? I think if it's always going to be attached the savings you would get from using 2x4 may not be worth difference in structural integrity you would get out of having an all aluminum frame.