And, we're off, sort of.

[Ceiii2000]

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.

[John61CT]

Totally freethinking here, experiment away!

High-density (400, 600?) 2" XPS core, great compressive PSI. Laminated to both sides insect screening for tensile, make a bonded sandwich; ideally steel, but aluminum, or even pet-proof plastic "superscreen".

Glue/paint likely epoxy, key will be those first bonding layers XPS to embed the screening.

Inspiration from the Mystery13 van tour vdo's

[Gator417]

I've been mulling over a very similar type of build for my Goldwing. The most likely scenario I've come up with is a fairly standard build, but with a door in the center rear to roll Nora in & out. Your VStrom is a lot more narrow than a GL (about 28" at the motor) so you'd have a bit more usable space on either side. Also thought about using a stand for the rear, like they use for race bikes, with built in tie-downs, so I wouldn't have to lean it over. She takes up most of my 5'w trailer when she's leaned over so she has to ride upright. My trailer is a tilt trailer, so I won't need a ramp, but my Nora is 600# so it isn't easy. I do plan on making a model of everything first. I don't want to get way in to it & find out its a no go.
Let us know what you come up with. If you're any good at Sketch up or something similar you should definitely mock it up that way first.
Good luck,
Gator