Hi there Kevin, welcome to the most informative trailer forum on the net. I may be able to answer some of your questions about your light-weight build, since I have a woody 8 footer that weighs 450 lbs with a sparce galley (no stove, sink or ice chest) I also have a super-light weight 6 footer that weighs in at 245 lbs, also with a sparce galley (just the wooden tear body weighs only 95 lbs). Then there is the latest one-off model, which is only 3 ft wide and 3 ft long, (with tip-out, slide-out and tip-up) which is slightly less than 100 lbs....total (no frame, axle, or springs, and no wheels at all, as it cantelevers off of the hitch on the car) %@*$#
It is encouraging to see that you plan to have 2 doors, good move, and are planning on using 1/4 inch plywood for your build. All of my teardrops have 1/4 inch or 1/8 inch exteriors, which has been no problem after ten years and 30,000 miles. Your plan for a 1/4 inch floor, should work out fine, (after all who ever stands up on a TD floor, and it is usually covered with a mattress) as long as the supports below are close enough together, (no farther than 12 inch centers). Now, having a removable pod is rather inovative, but such thinking out of the box, makes it even more interesting. If you plan the have a natural wood finish on the exterior, keep in mind, sanding and re-finishing once a year will be required. For use in Canada, I suggest alum or FRP exterior material, or something similar.
Lastly, if you have any concerns about it's aerodynamic properties, I have often felt that unless you plan to strap it onto the nose of a rocket and have it shot into space, round front, angular front, slanting front, probably won't make a bit of difference while you are towing it a normal highway speeds, which by the way, here In Calif. is 55 mph, max. Others have expressed the same opinion, since turbulant air follows your hauler.
If you do a little research here on the board, you will find builders who have converted pop-ups to teardrop configuration. I wonder how much alteration you will have to do to slim the frame down to fit a 4x8 sheet of plywood. Another concern, (probably only in my mind) is the size of the wheels and tires. I'm all for at least 12 inchers, but others seem to do just fine with 8 inchers.
I hope this answers some of your questions, and bear in mind, these are only my opinions, since most builders use heavier construction materials which of course adds greatly to the final weight. All of my tears are being pulled with a 4 banger engine with no problems at all. If you have any further questions about my suggestions, feel free to PM me, as I will always answer requests regarding my off-of-the-wall construction ideas. Hey, they work for me, and that's what counts. Good luck on your build, be sure to take pics to post on the board, and you better hurry up and make some sawdust, right away.
Roly Nelson, the li'l ol' So Calif TD builder.......Me! ~~
