Thanks guys for the excellent advice / feedback. This design has been evolving for the last 5-6 weeks. And this one will undoubtedly be revised several times before I start building. Here’s how I got to this point.
My original idea was to build a Kuffel Creek Cubby on a HF frame with some modifications to the galley to suit our camping style. After reading some posts on this board, I decided the 45 ½ interior was just too narrow.
I started exploring alternate trailer frames to allow for a wider tear. For a time, considered welding up m own 5 x 8 foot frame. However, my welding experience is limited to a few hours playing around with my son’s 110 volt flux core welder. I decided a trailer frame was a bit too much for a first welding project. Also, I don’t think my son’s welder would provide enough penetration to safely weld a trailer frame. While exploring that idea, I took a good look at the construction of the Snow Bear 8000 utility trailer that bought last year. It’s 54” wide. This allows an inside dimension, of 51 ½ (assuming 1 ¼ walls). That is just 2.5” narrower than our standard full size mattress. We can live with that.
In addition, the Snow Bear’s frame has some nice features that make it an attractive platform for a home-built tear drop. The frame is fully welded and supports 2,000 pounds. The axle position and tongue length are adjustable. So, I can fine tune the trailer’s balance after it is built. It comes with heavy duty steel fenders that bolt directly to the frame (yes, they adjust along with the axle). I can get another Snow Bear trailer at Lowe’s for $700. It’s about what a decent 220 Volt welder MIG welder would have cost me.
While playing around with the cabinet design it occurred to me that the Cubby’s lines, while pleasing to the eye, waste lot of space, particularly in the rear. I eventually found Andrew’s Rimple design and here I am. Besides allowing for a deeper galley, the Rimple’s flat surfaces roof and front present the possibility of adding a front window or a even moon roof.
I plan on wiring the trailer for 12 volt only. I want to make the electrical system as efficient as possible by using fluorescent lights for the main lights in the cabin and galley with LED reading lights installed in the front of the cabin. I plan to install a car stereo, but have some lingering questions about the stereo that I’ll post on the electrical forum.
My side walls will be 1 ¼ thick. 3/8 ply + ¾ framing and insulation + 1/8” birch ply on the inside. I found a local source for 1/8" “bending birch” ply
http://www.boulterplywood.com/ that I’ll use on the radiuses.
After reading about Steve Wolverton’s tear, I decided to cover the roof with 1/8” ply and fiberglass the exterior. Hopefully, I can come up with a cool decorating theme for our tear. Maybe I’ll do a two-tone retro-50’s paint job.
Andrew, I hadn’t considered the galley hinge. After thinking about it, I worry that a piano hinge might be prone to leaks. So, perhaps Grant’s galley hinge is the way to go.
Tom, your barn door idea for the lower galley is very interesting. I’d love to see some pics when you get it done. Take care guys and thanks again for the input.
So I am taking these photo's in rather crowded conditions. I do get the full garage while she is at work and on weekends. My God, I'm talking like a divorced person. 
