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If you were manufacturing these every day. You would be able to have the metal hot dipped galvanized and not worry about all the rust. There frames are probably totally welded up before going to the dipper. I will say that working with tubing is a lot easier then working with the channel...

I am trying to figure out why you want to go through all of the work for the uses of tubing? You can get a 1/4 thick C channel to do the same thing. The supports that you will hang the spring saddles on need to be 1/4 inch wall thickness. Tubing does great for interior walls that need...

Check with Buyers products. They were a lot cheaper then Highway. I am a dealer for Buyers. Message me with the specs and I will see what I can do for you. They have NEVER been more then 2 weeks on full custom built boxes.

2 x 3 x3/16 would be overkill on something that small. The weight is 3X that of a 2" C. Big production uses coated material for the Tube frames

1/4" luan on two sides with 1" ethafoam in between is cheaper and better r value. Pull the plastic wrap off of the foam before you glue the luan to it. It is unbelievably strong. For $35 dollars you can make up a panel and see how light and strong it is. Cheaper then $265. 2" C channel can...

Hinge the camper off of one side. reinforce the back door area with an internal metal frame. Add some canvas. $200 and now you have a nice stealth camper.

If you are concerned about weight. I would not use 4" C. You had planned on a 2" Tubing. Just use a 2" C In its place. The wall thickness is twice that of the tubing. Making the welds stronger. The cross members spacing is based on the flooring material. 3/4 inch plywood, you could go...

Tubing is unidirectional, where as C channel has strength in one direction. Allowing the metal to be thicker and weld stronger. The tubing is thinner walled all the way around and the welded areas are weaker. Your strength on the tongue is 90% downward. That is where the strength of the C...

As I look at the floor plan, it reminded my of why I goot rid of a standard floor plan camper. No Open floor space? Two people and normal winter gear filled up the floor space on our Lance camper. So I started looking around and found the Lance 1040 floor plan. The biggest difference was the...

Nice.

Different parts of the trailer should be made of different material based on the structural strength needed in each application. The tongue itself should be C channel. Structural areas may be angle or square. As a whole you would not want any more closed area then necessary. These are areas...

You might also find that you can extend the tongue of the trailer, as well as just removing the jack in order to tow straight off of the hitch without an extension.

How have the fill hoses worked out? A lowered bed will cause problems if you do not work it right.

Remove the lift and add the proper springs and you should be good to go.

A cat eye bolt installed in one of the holes of your swing out bracket. Then install a plate or directly mounted to the bed just above the round clearance light. This gets the anchor out of the way of your boxes.

I was able to use the jack location. As a tie down spot. I bet If you go ahead and mount the boxes so that they can be used all the time. as compared to using the camper as art of the storage box as some have done. The jack locations should be away from the boxes. I used a 6 inch plate...

I have done what you are trying to do. I have a rubber mat on the floor of the flatbed. I use spring tensioners on all four corners. Along with short pieces of chain that are longer then the spring in max load position. It has worked perfect. I wil admit this to you and nobody else. The...

Have you thought about adding structural support to the plate directly under the winch. And add gussets to the mount bases. I see the winch bending the plate in the middle and the feet bending from the rear ward leverage of the pull.

That is a great looking rig. Keep us posted on your adventures.

My setup is only 11' 4" You might want to cut into the bed rails in order to lower the bed and camper. I start with the height of the cabover and build the bed to that height. You should only need 4 inches for the camper to sit at the right level.