hi folks Im a hobbyist welder but not an engineer by any means. Im planning to build a custom aluminum utility trailer. Its 14ft overall and fairly narrow. The deck will be 45" overall about 65" Heaviest thing it will carry is an 850lb motorcycle. I have this idea to make the deck flush with the frame. The deck wood will span the whole frame, that is, go right up into the V at the front. Got the picture?
the main frame is 2x3 rectangular tube (3/16).
1.5 x 1.5 x 3/16 aluminum angle will support the deck
but at the front there are two main cross beams. These will be 2x3 like the frame
the tongue will cut though the first beam and weld to the 2nd BUT
Since I'd like to make the deck flush with the frame, now those two front beams have to be 1.5inches lower so if you can imagine, something is not going to line up.
The two front cross beams will be 1.5" lower than the frame and the V parts of the frame and the tongue will be off as well... the tongue will be 1.5 lower than the rest of the frame.
So at 0300hrs in the morning I said to myself, "Self, we are losing a fair bit of area that would have normally been welded up to.... the tongue will be 1.5" lower than the V so only 1.5" of that will be weldable (eg less surface area)
I'm guessing I can fill in the gaps with scrap aluminum and weld around it. Id like to know about structural strength and also concerned a bit about aesthetics too.
Come to think about it, I don't know any welders who are engineers. Most I know, just build it and assume it will hold together.
Let me know what you think. Thanks.
