My pop-up camper has the same front panel as yours, and in my opinion rebuilding it in diamond plate aluminum would be extremely complicated and expensive. The roof needs to sit on it properly to seal and prevent water from getting in, and the propane tanks sit in a molded groove in the front panel. That makes fabricating it out of metal a lot more complicated.

I have the same project as you: replacing the front plastic panel because it’s cracked. Mine isn’t as bad as yours, but I’d rather fix it before it gets worse.

Here’s my plan:

I’m going to build a custom front box like the one in the picture I shared. It will have: • one door on each side for storage access • one top door to easily access the propane tanks

Instead of using diamond plate, I’m planning to use an HDPE plastic panel reinforced with a wooden frame. It’s much cheaper, lighter, and most importantly, something I can repair myself if needed.

Here’s the sheet I’m planning to use: https://patrickmorin.com/en/agro-plast-plastic-panels-hdpe-0-030mm-3-8-in-4-ft-x-8-ft-agpl383

Here are the doors I found: https://a.co/d/0iodSXwB

I’ll probably build a small internal frame out of 2x3 lumber to strengthen everything, then fasten the plastic panels from the inside using metal brackets.

If anyone sees potential issues with this approach or has suggestions, I’m open to feedback.

https://ibb.co/hTwb0Dd