You keep it light by using a skeleton of aluminum or steel tubing and covering only the critical parts. Use composite panels where you need insulation but not a lot of weight, and bolt everything in a way that lets you take it apart later. Don’t over‑rigidify; a little flex is better than a brittle frame that’ll crack under road vibration. Keep the power system separate and use lightweight batteries—maybe a lithium‑ion pack instead of the old lead‑acid. Finally, test the whole thing on a track before you hit the highway; a quick roll test will reveal weak spots before you have to fix them mid‑trip.

Sure thing, I’ll keep a close eye on the terminals and use proper thermal management—heat sinks or a dedicated ventilation path. As for the route, I’m eyeing the coastal stretch first because the climate is milder and the charging infrastructure is a bit more reliable. If the desert calls, I’ll swap in extra cooling pads and a larger battery pack to handle the heat and distance.