Good thread...
I was also thinking about extending the stock lunette or having one fabbed up. I towed this around with the lunette/pintle setup, and was impressed with how quite it was actually? I think I am going to stick with it for now... but the short trailer is a wee bit of a challenge when backing up.
I am very impressed with the mods I have seen on many of these trailers, the bike rack rear receiver is on my task list as a needed mod ASAP. I have been researching some designs, and making some plans.
If you were to use DOM to extend the lunette by say 12-18", and used a good amount of overlap as mentioned above, could you not drill through it and use say a grade 8 bolts as added security? I know the welds should hold for an eternity, but the mechanical/shear strength of a grade 8 bolt would certainly add a little extra comfort no? Probably not needed...was curious?
Just thinking out loud. Thanks for sharing your designs and ideas!!