So I am starting a foamie hybrid toy hauler. Think converted cargo trailer only I am starting with an HF frame that I am heavily modifying. I got a dexter 2200# axle and 13 inch wheels with better tires to start. I have the trailer disassembled and am learning to weld so I can make it into a 5x10. The finished trailer should be 6wx10Lx6H. I do however have a plan for a slide out that will use the rear ramp door as the floor. All weighing in at less than 1600# with my 2013 650 Vstrom in it.
Ok so here is the first thing I would like some input on. Anybody have an idea how I can build a ramp door out of foam that will take approx. 800#? What should I laminate it with? Epoxy and fiberglass? Would PMF hold up? Maybe some kind of stack? The walls and ceiling will be 2" foam. The floor will be 1/2" plywood with 2" foam glued to it, the frame plywood and foam will all be covered with PMF. I would like the ramp door to be insulated the same amount. Any ideas would be greatly appreciated.
Or should I just weld a steel frame and encase it in foam/laminate/canvas? I would rather not use the steel frame just for weight savings. Although some steel at the bottom may be needed to weld hinges to it.