switterstx wrote:What happens if I'm over or under the weight range by a couple of hundred pounds?
Being under the weight range is no problem as long as you are at least 50% of the axle rating, and preferably 60-70%.
Listening to the guys on the FiberglassRV forum who tend to need to replace their rubber torsion axles after 'only' 20-30 years of use, when many have been loaded right up to their rated maximum, and some well over it, I don't think you need have any concern about using all the axle rating of a rubber torsion axle, or even overshooting it by a little.
So aim for a trailer weight that's 75 or 80% of the axle rating and you are unlikely to have a problem. At your estimated 1000lb trailer weight, that's an axle rating of around 1300lb. I guess it's better to undershoot than overshoot, so maybe a 1500lb rating would be a good choice. Then you would have to build your trailer at under 750lb (loaded) to get the problem of the axle being too stiff.
Andrew