Ok after patiently watching for a used trailer I found one. Not ideal but for $120 even changes I want to do keep it well below a new one. And it's the only the second one that wasn't a rusted POS for under $500. This one is rather light weight too.
Was obviously home built, has an axle that has the brake plates but maybe 1" clearance between those and trailer frame. 1.75 axle so at least 1500lbs (perfect). Will need new tires.
Im going to extend the tongue 12-18", rear of trailer 12". Not sure which plan I'm going to use to raise the deck from the axle as shackles are obviously welded in.
Design:
Walls I'm thinking of simply overlapping the wheels partially so I have 4ft wide internal space (have to fit me and wife).
Internal height will be about 4.5', enough I can kneel inside without bashing my head constantly. Main space will be 7ft long inside. The extra 12" is not for galley space though. This comes to my design idea I'm working on to solve a problem: 3 yr old and 10 yr old boys.
Not doing the Tear drop shape. Just a box with half the front wall angled back a bit.
At the back there will be a bunk above the foot area wide enough for the 3 yr old, length is that if internal width. Will be accessable from inside the main area or the rear. Privacy barrier will be able to be put up between main and bunk/rear. Aka between us and kids.
The rear hatch is what I'm working on now. And this is the "problem". A lot of sites here you have an option of either trailer/camper or tent. Both cannot be in the same site and we're talking a good amount of space (sometimes 100s of feet) between where campers and tents are. So need to have a space for the 10yr old.
My idea:. Either a split rear hatch or an overlap (when closed) where the top is the external hatch then inside is another deck that folds down. Bottom deck would have a secondary flip out to give him the extra length My 10yr old is too tall already for a secondary simple bunk. But since he's from my previous, we don't get him but maybe 1/3-1/2 the times we camp (every other weekend thing). So the option of not using his space and leaving it closed is why the bunk will be accessible from the inside.
Then make us one of our tents to make 3 sides (one with the door) for him.
Goals:
Loaded weight (try to be able to fit 4 bikes on the trailer and keep it in weight) is 1500lbs.
Built on the best possible compromise of price vs how long it lasts before wood goes to crap. The "foamie" thing I'm having issues with. Sleeping in foam box just bothers me. So thinking if framing, 1/2 external ply using the "mix" (the 50/50 stuff I've been reading up on) for all sealing as much as possible then the glued on canvas that gets painted (PMF I think is what you guys call it). Right paint for that can do awesome things. Framing will be kept as light as possible except doors, leading corners/roof joints and bunk/hatch support.
I'll get into accessories later since none of that besides running electrical (will have solar/deep cycle for self supporting LED lights and usb ports) is going to be messed with for a while. Though an AC unit for when we have shore power (more often than not) is under consideration.
I don't expect this one to last like some of the good ones, but for a few years and to learn from.
Long read, apologies, hoping guys take the time to read it all and any ideas/advise is greatly appreciated.
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