Hi Russell, this is the place, if you want to get advice on how to build that teardrop. I have built a couple, (you can't just build one) the first one, which is on my web page, weighs in at about 500 lbs and I can lift the 12" tire off of the ground, using my 75 year old muscles. If you really want to build light, my 2nd one tops out at just under 250 lbs. However it is only 6 ft long. A 4x8 tear is the most ecomonical and is just right for a couple of newly weds.......and the wife and I, even after 54 years of wedded bliss.
As far as the size of the door is concerned, I feel that when you sit on the mattress, you don't want a hard board cutting off the blood on your upper legs, so the bottom of the door should be well below the top of the mattress. Then, while sitting there, you don't want to bump your head on the door opening, so I made mine as high as possible. As far as width, the wider, the better. It makes swinging your legs in easier.
You might want to log onto the Harbor Freight web site, and check out the trailers they have that will suit your needs. Many folks have custom trailer frames built, some weld them themselves. Both of my tears have 12" wheels on HF frames and they both work great, even after over 10,000 miles. Often the HF frames are on sale and can be ordered to be delivered to your door.
Good luck on your build, ask questions, take pics and post 'em!
Roly
