Hello folks!
First-time poster here. I've been reading this forum for a couple years now, and searching/browsing it has answered SO many questions. But I'm FINALLY about to start my build and I'm kind of stuck on one important decision.
Is it better to go lightweight or opt for a sturdier build for a SMALL trailer?
I'm building a 4.5 x 5.0 foot gear hauler over a 40"W x 48"L aluminum, bolt-together trailer.
I'm waffling between to different methods.
1: All floors and walls made from 1x2s and foam board sandwiched between 1/8" Baltic birch plywood (I've already got all the wood for this).
2: Floor cut from a single piece of 3/4 plywood, and walls/ceiling made from 1/2 plywood and 1/8" Baltic birch with hollow walls for wiring (I would just have to purchase the 5' x 10' sheet of plywood for the floor).
Lightweight Build
PROS
Lighter weight
Less expensive
CONS
More fasteners = weaker joints in floor
Less strength to support 6" overhang
Heavyweight Build
PROS
Stronger floor
More mounting options inside
Added strength to bolt-together trailer
CONS
Heavier*
More expensive
The trailer is rated for 1000lbs. The lightweight build would come in around 100 lbs. while the heavyweight build would be around 225 before adding all the extras.
This is a pretty small trailer. It will have a galley in the back, but the front will be mostly used for storing bulky items like tents, sleeping bags, sleeping pads, a big cooler, and a spare tire. On top, I plan on carrying two adult and two kid-sized bikes.
*So, is heavier really a con in this circumstance? Would the sturdier, heavier build actually help the trailer track better? Is the waterproof plywood enough, by itself to justify the heavier build?
I'd appreciate any opinions--I'm anxious to get building, but totally stuck!