Building trailer...assistance needed please!

[Spicy McHaggis]

Okay so I'm starting on my off-road capable trailer build. This is going to be a dual-purpose trailer, as I'm active duty Coast Guard and it'll be hauling our camping gear, clothes, and other necessary stuff when we transfer. The rest of the time...hunting, fishing, and camping gear will find it's way into it.

The outer frame is 2x3 .120 wall, the cross pieces are 2x2 .120 wall. 3500# axle, 15x7 steel wheels, 31" all-terrain tires.

Okay so I've got a flat platform...now I need to figure out how to do the sides and a lid.

For the sides, I was thinking about using 1x1 .120 wall steel tubing. Then I started looking around and saw a lot of people using 2x2 .120 wall tubing. Would 1x1 be strong enough?

Am thinking about getting some diamond plate for the sides (flat sheetmetal for the floor). What's the best way to secure that to the side posts? I'm going to do an "external frame" on the sides, so the inside is smooth.

I've got a tailgate figured out, just need to build it depending on what I use for the sides.

For a lid...not sure what to do here. The lid is to keep things secure AND weather proof. Thinking about using some 1x1 tubing as supports and hinging it at the tongue end of the box. Anyone have any suggestions on the best way to go about doing that?

Thanks in advance!
Spicy

[UK4X4]

1X2 but mostly 1" tubing for the boxes

aluminum plate riveted

http://expeditionportal.com/forum/sh...t=consolidated

[ntsqd]

If you are not going to weld the sides to the side frames then I would suggest that in addition to the suggested rivets that you also use a structural adhesive (like one of the Silkaflex products) between the panels and the frame. I suggest this for two reasons, You'll gain some strength and rigity for little extra effort and it will seal the panels (presumably aluminum) from the frame (presumably steel), which will make the trailer more resistant to water & dust infiltration and remove the possibility for electrolytic (dissimilar metals in contact) corrosion.