Got back Monday evening without any more issues. I ended up using a ¼" bolts and Nylock nuts to lock the panels in place instead of zipties.
Since the return trip was during the day, there were a lot of gawkers and photographers shooting away. Had one police squad car shooting piccies, one driver had to do the drive around (left, right, and rear shots). A few drivers did their best to slow down to shoot piccies...even to the extent of pulling off the road to wait fer me. I believe there were a few that drove out of their way to git some piccies and then turned back around.
The gap covers did their job without any problems. I'll be revamping the upper gap cover in the near future and see how a clear sheet will perform over the Lexan roofing panels.
Since the side panels haven't been contacting the road, I'll be looking to enclose the exterior of the trailer to the level of the side panels and see how that works out on the next road trip. Maybe a belly pan fer the trailer, too!
I did reuse some baseboard and covered the gap between the gap covers and the aero cap. I'll have to add more fer the top part.
My mileage the trip going out was 25.5mpg and 24mpg coming back. Too many stops along the way combined with small town 30mph speed limits on the way up and back was the killer. Indicated highway mileage was 27mpg going out and 28mpg coming back. This was my first trip out to Castle Rock, MO with this setup.
Strapping the luggage down in the trailer seemed to minimize the trailer bucking. Will have to experiment with this setup some more.