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I've been down this road a few times. I've never owned a pop-up, but it makes no difference regarding the concept. I also wanted the pass-through access for our dogs. Initially, I used an inflatable boot that spanned the width of the cab. It worked well to seal the opening against the elements...

I took that truck for a couple of test drives a while back. While I decided it wasn't right me at the time, it appears to be a solid truck in good shape. I didn't notice any issues at all. I did have the same thoughts regarding the overhang, though. PM me if you have any specific questions.

You may be able to modify your cooler to your needs. I have an Igloo Marine cooler, as well. I built a Reflectix "cozy" for it that covers the top and sides. I sit the cooler on a piece of 1" Styrofoam inside of an old sleeping bag or blanket. If I'm stationary for a while, I'll cover it with...

I did this about 25 years ago with a steel high-top Gem Top shell. I bought my windows from a local manufacturer but they were standard RV windows; about equal dimensions on the four sides but in a parallelogram shape. The shell was just the thin steel skin supported by arched steel members. I...