Well, gazza, you've won the all-time epic thread award on this forum, I think. Some project. Reckoning you can do everything on the absolute cheap has it's drawbacks, I guess. The trailer project has to run second. I tried to find your original rant on how we were being "ripped off" with trailers, reckoned you could build one for 2k in aluminium. Designing from scratch always brings up issues--when I built my own, steel then galvanised, I just sized off the existing, went up in material thickness everywhere, and added a little bracing. Still took a while.
I'll give you an A+ for persistence.