Here's a diagram of what I'm attempting to build. I'm naming "The Wedge" for now.
The attach point for the tongue I planned to be 2X4 lumber laid flat sandwiched between 1/4 inch plywood both sides as the floor. There will be 4 2X4s in all going all the way across the floor, one in the front , one just in front of the axle, one just behind the axle, and one at the rear sticking out from the floor 7 inches on each side to mount the lights on. the lights need to be out that wide so you can see them clear of the 60inch wide of two canoes. The rest of the floor frame lumber would be 2X2.
Tongue steel all the way back to the rear bumper would be about 12'9". That would put 7 ft under the trailer and 5'8" sticking out. This adds about 13 lbs using the angle steel and when you're pulling it with a Hyundai Accent every pound counts. I read somewhere on here that it is best to have as much tongue under the trailer as sticks out.
The current tongue I have is 2.5" square tube about 8'6" long (102"). Coupler adds 3.5" to ball
That would be 68" in front of floor and 37.5" under the trailer if I use it. Plus side to this is zero cost except the mounting hardware.
I plan on mounting the tongue the way the Pico Light design is configured. That thread shows doing it both ways.
I plan to have this thing weigh under 350 lbs and it is only 7 feet long. But I have to consider there will be 80 to 100 lbs of canoes/kayaks on top, so in reality it will weigh in at 450.
The questions I present to the experts here is: Can I use 2X2 angle 1/8" thick sticking out that far or should I go with 2.5 inch angle in a 3/16" thickness? Or maybe a combination or both tongues. Or am I over compensating and the steel tube I already have will be fine.
Here is my rough weight calculations which I consider to be like estimating the costs, that is add least 30%. Do any of these weights sound way off?
150 1/4" plywood 6 sheets @ 25 lbs a sheet
31 tongue steel 18 ft 2 X 2 angle
64 axle and springs
48 hitch, receiver, and ball. Yes it added that much weight to my car.
15 tongue jack
19 spare tire
10 jack and lug wrench (the car doesn't have one, and no I'm not kidding...no spare...just an air pump.)
337 total
Use 1/8" ply for 3 of the six sheets would cut 37 lbs = 300
Do without the tongue jack cuts 15 lbs = 285
Remove extra leaf springs might cut 10 or 15 lbs. The springs are rated to 1000 lbs.
Tongue steel all the way back to the bumper 12'9' long would weigh 43.6 lbs adding 12.6 lbs.
Add in the weight of the 2 by lumber in the floor and the 1 by lumber in the walls and roof.
Add screws, bolts, glue, hinges, latches, door latches, and paint. Your guess is as good as mine. That's what the extra 30% is for.
When I put those calculations together what set me back a bit was the weight of the plywood is almost half of the total.
