The goal was :
1. aerodynamic to save gas and pay homage to the original teardrop trailers. Thus, the shape.
2. Lightweight to save towing capacity for gear.
3. Just big enough to carry the items I wanted, my folding cot is 2" shorter than the width inside.
4. An experiment to try building with composite construction techniques.
The harbor freight trailer was used to aid in registration, next time I will skip that part. After carefully measuring, I cut 8" out of the middle of the frame before welding it together. 8" removed from middle of the axle too, then weld.
Exchanged the steel tongue for a length of 2" square aluminum tubing ,saved a bunch of weight.
Exchanged steel fenders for plastic, more weight saving.
The materials to make the box were also chosen for weight savings while maximizing strength, that's what composites are all about. 3mm marine plywood laminated to 7/16" foam insulation board with marine epoxy makes a very strong? Lightweight, panel. When combined with fiberglass cloth, it gets even stronger with minimal weight added
To pull off this trailer, I read a lot of articles and build logs, used my existing skills of welding, woodworking, and kayak building, and made educated guesses along the way. So yeah, I just threw it together.