Building My Own Camper - Welding Advice

I've been thinking about building my own camper shell, or rather, just a high top contractor cap.

My truck, a 2006 Tundra, for whatever reason is a rarity when it comes to availability of utility/contractor style aluminum canopy shells. Not to mention that I'd like a "high top" variant...and with some custom options (a window that swing in from the cab). To buy what I want new I'm looking at $2000 or more.

It has been suggested by some that instead of TIG with gas or MIG with Aluminum Spool Gun, that I instead try brazing with torch and aluminum/zinc rods. The advantage being that it's cheap and will allow me to more easily experiment with construction techniques while building the canopy, and not get so caught up on merely learning to use a welder. 

My worry is that without much penetration, this style of construction will be pretty weak. 

Of course the other options to build the shell frame out of 1x1 steel square tubing, which should be cheaper for both materials and welding equipment. It will just take some thought to keep it from being a 500lbs mass of steel. 

Thoughts?

IMO brazing will not hold up. welding is used for a reason. 

Now you could go ticker panels and rivet/bolt and glue it.

Brazing if done properly, will hold up fine. The joint can be stronger than the parent material.  The reason it is rarely used is that the process is very slow and high quality brazing rod is not cheap.

I'd say build as much as you can out of steel, then rivet on aluminum skins.

Fiberglass?

Have you heard of GoFast Campers? They might have some good ideas you could borrow for your shell design. 

In reply to thatsnowinnebago :

Yep, know all about them. Hoping to see them at Overland Expo West and take lots of pictures.