Originally Posted by mgmetalworks
For reference (see my website), I know its a little smaller than your box idea but the tailgating trailer I built years ago was a steel frame, aluminum skin "box" and the whole trailer weighed 1750 loaded with full propane, half keg and all the gear. We used rivets and VHB tape for construction and it is super stout. It survived a trip into a deep ditch where it went 50+mph to zero in about 3ft. Bent a corner of the frame and ripped some panels but it was fixable. you'd be surprised how rigid a 1" tube frame skinned with 0.080" aluminum is. VHB tape is the bomb too! The base material ripped apart all around the bond surface. It's legit!
I'm fully on board with VHB Tape and rivets!! I think people would be shocked at what is held together with that. I did check out your trailer! Everything on your site for that matter, I am a lurker for sure.
My buddy was also telling me about some 3m epoxy that is used for panels and it becomes stronger than a weld. I think it's 8115. But VHB is the stuff!
I guess one of the issues is that I am jealous of ambulance builds, all that nice space in there, but I would want SRW and a pop top bunk for the kids.