STEP 1: WELD FRAME
First you need a frame to design your trailer around. You can start from scratch or try an easier route by finding a previously owned utility trailer and using that as a starting point. Garrett purchased a 4 x 6 utility trailer on Craigslist for around $200. The frame was badly bent but the torsion axle, hubs, wheels and fenders were all in pretty good condition – plus it came with a clean title. Garrett removed the axle from the original frame and built a new frame from scratch.
Using 2″ x 0.12″ A500 Steel Square Tube, cut the desired lengths, based on your design, with 45 degree angles at each end. The new trailer frame for this project kept the width of the original base, 4-feet, to allow for the use of the original axle. The length of the new frame is 7-feet to accommodate the design of the trailer (see step 4). Weld these pieces together to form the new frame. Test the fit and attach axle to frame using 1″ x 2″ x 0.12″ A513 Steel Rectangle Tube to create the spacers between the frame and axle, join by welding.