Hi, I'm Scott and I'm so happy I've stumbled upon this great online community. I'm really interested in building a tear that will house my young family. It's my wife, myself, a 5 year old and a 2 year old. I'd really like to build something on a bolt together frame that will house all of us for a few years, as I have lots of woodworking/composite experience but virtually no welding experience (beyond the brazing and arc welding I did in 8th grade shop class, I'd rather not talk about how those joints looked). I'd like to build something simple, fairly large and fairly light. I'm towing behind a 2000 Toyota Sienna that has a 3,500lbs tow rating, but as I do most of my camping west of the Eisenhower tunnel, something less than 2,500lbs would probably be ideal. I really like the idea of the foamies.
Here's my biggest question, how big can I go on a bolt together frame? From what I gather, the largest bolt together is the 5x8 Tractor Supply trailer. Beyond that it seems that you have to go into drop ramp landscaping trailers that all seem to be north of $1000 and have a lot of parts that would need to be removed, which would seem like a real waste to me. I understand that used trailers are easy to find in many areas of the country, but I live in suburbia so I don't see too many laying around on back lots and there doesn't seem to be any on craigslist.
I'd really like to build something on a 5' wide frame with an interior in the 10'-12' range along with the traditional rear galley. That size would tuck in behind the van's slipstream and reduce frontal drag and I have to imagine the sloped rear section helps to reduce what I can only gather is induced drag (former airline pilot here, so I only know drag by way of aircraft design). I've been searching through the projects and have seen some examples of larger trailers, but nothing like what I'm describing. Do you guys know of any designs like this?
Thanks in advance, Scott.