Yes, Foam is really Strong when used right !!! We may have talked... a Lot , but it was just to promote the idea of Foam trailer building ... Now , everybody has realized that this works , so we have to do much less explaining !!
Razz, Curves would be Nice (and prettier too), but are more difficult to do ... The intention of the “VSF” was to design a trailer that Grandma could make with kitchen utensils ... No curves, no kerfing , all straight cuts , save that one angle cut (bevel) on the nose sheet where it meets the roof ...the sides are just a full uncut sheet of foam laid sideways, nose triangle glued on (simple ) ... and actually that sloped nose does act somewhat like a curved surface , adding stiffness to the box .... it’s the angle (theoretically 45 deg. angle would be “ideal” )... With the angle on the nose and the rear wall in place, it should be Plenty strong enough ... when built to the proportions shown...
Bigger builds might require some inner bracing , easily done with shelves and cabinets built in ... Gotta’ remember , every time you span between two points (like putting a shelf between two walls) You connect those parts together as a unit , which substantially strengthens that whole “unit” and prevents any flexing between those two points... and in reality , we do tend to build things Much stronger than they need to be
...but that’s Good as long as the finished trailer is light enough to tow comfortably ... and carry the 500# of Beer and gear ...
Ps. i believe the optional "Beer Ballast" was mentioned later on in the Big Thread !!! Keep reading !!!