Hello, I'm slowly planning on making an ultralight trailer to tow behind my fiesta and I was looking for advice.
My priorities are to make a trailer that is basically just big enough for a bed while making it as light as reasonably possible without compromising too much on integrity. My plan is to base it on a welded aluminum frame using a split torsion axel
, with a distribution system that uses a solid aluminum bar core for the axle substitute, a 2" hollow bar from hitch to tail as a spine to support a 1" hollow bar frame, a thin sheet of something rigid for the bed, then a lightweight shell with .75" or maybe .5" angle bar for support and with rigid foam with a truck liner exterior and not sure what for the interior yet. I haven't figured out what i will do for doors as it seems it's best to buy premade.
My current estimate is that the trailer will weigh about 400-600lbs and cost about $2,000-$3,000 excluding doors and fixtures that will likely add another grand. Plus I'll likely need help with the welding as I don't have the right equipment so that will cost more
The pictures are as below. the dark pads are solid aluminum for bolting on the split torsion axel
along with the stabilizer jacks
(using one in the front instead of a standard jack because the trailer will sit low to the ground - my car is also low profile anyways)
i intend to put two doors on either side that are as big as possible, I don't think i can make them from scratch and be fully weatherproof so I need to find ones that aren't full height and make adjustments to fit them. then add some windows i can open
, a roof vent, wiring and bolt on a coupler, and it should all be good to go.
I'm still figuring out exactly how I want to do the upper shell, as I'd like to have rounded edges.
It's still in the planning stage and there's a few things i need to figure out still. I just found these doors
which should work...