How to Reskin a Cargo Trailer: A Tips and Tricks Guide
Posted by Dayne W on
Over time, the exterior of a cargo trailer can become scratched, dented, faded, or damaged. Whether it’s due to weather, road wear, or just age, reskinning your trailer with fresh aluminum panels can dramatically improve its appearance, durability, and resale value.
In this guide, we’ll walk you through the tools, materials, and process of reskinning a cargo trailer using painted aluminum sheets.
🔧 What You'll Need
Materials:
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Painted aluminum trailer sheets (.030", .040", or .050")
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Self-tapping screws or rivets
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Butyl tape or sealant
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New trim (optional)
Tools:
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Drill with screw/rivet attachments
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Putty knife or scraper
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Tape measure
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Utility knife
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Ladder or scaffold
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Safety glasses & gloves
🗂️ Step-by-Step: How to Reskin Your Cargo Trailer
✅ Step 1: Remove Old Panels & Trim
Remove any existing trim, corner caps, screws, or rivets. Carefully peel away the old aluminum skin using a scraper or utility knife. Avoid damaging the frame or insulation.
💡 Tip: Take photos before disassembly for easier reassembly.
✅ Step 2: Inspect the Frame & Make Repairs
Check the frame for rot, rust, or damage. Replace or reinforce as needed. Ensure the surface is clean and smooth before installing new panels. Make sure to remove old sealant or tape and sand to a clean surface.
✅ Step 3: Measure & Cut New Panels
Measure each wall to double check that the painted aluminum sheets cut to size go in the right place. Common trailer skin thicknesses are .030", .040", or .050". For custom work you need to do yourself use metal shears or tin snips for clean cuts.
✅ Step 4: Install the New Aluminum Sheets
Apply butyl tape or sealant to the frame where the panels will be mounted. Postion the sheet and peel away the film on the tape. If applying multiple sheets, make sure to start from the back so the overlapping seam faces back and not towards the front. For a secondary measure of mounting, use the self-tapping screws.
🛑 Reminder: Overlapping seams should face the back of the trailer.
✅ Step 5: Reinstall Trim and Finishing Touches
Reinstall corner trim and edge molding. Use butyl tape underneath for waterproofing. Caulk all seams and joints. Clean the trailer and enjoy the transformation!
🧱 Should You Use .030", .040", or .050" Aluminum?
| Thickness | Best For | Notes |
|---|---|---|
| .030" | Light-duty trailers, easier installs | Flexible, but less impact-resistant |
| .040" | Standard exterior siding | Stronger, good balance of weight & durability |
| .050" | Heavy-use or commercial trailers | Very strong, more rigid, adds weight |
🧰 Bonus Tips
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Replace trailer lights or reflectors while skin is off.
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Check the weather forecast before starting this project outside.
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Use color-matched aluminum for a factory finish.
🔚 Final Thoughts
Reskinning a cargo trailer is a rewarding DIY project with the right tools and patience. New aluminum panels can give your trailer new life and protect it for years to come.
Need materials or advice? Contact us here with any questions or comments!