IdBdan said:
The only reason I'm building this myself is because it has been impossible to find a manufacturer to build it. Tried for 3 months. Searched the entire east coast from New jersey to Florida. Even the custom trailer builders won't build it because they have so much standard work they don't need it. The big manufacturers all have a standard line of trailers and they don't do custom. And if they will do it, it's a 6 month wait. Right now torsion axles are a 24 week wait. There's one manufacturer that will give you 6 weeks but at twice the cost. And reason #2 - Aluminum builders are scarce.
The other thing I found is that most don't even have an engineer on staff? Their working off 30 year old designs in some cases. And when they fit bunks for boat trailers they use the 60/40 rule for axle location & tongue weight ... and that's it. The most important part of trailer safety is the tongue weight ratio!
Any trailer under 26000# is virtually unregulated. They don't fall under the Title 49 Code of Federal Regulation, Parts 500-599. They have a handbook with 100's of pages and 2 paragraphs on trailers. If you call, you're told to contact the National Association of Trailer Manufacturers and buy a membership for help. A non-Government entity.
And all the important parts of a trailer (axles, brakes, hoses, lights, receiver, etc.) are the part manufacturers safety responsibility. The only responsibility for safety in a trailer build is engineering and the fabrication processes.
So in reality, I believe I'm doing a better job of 'regulatory safety' than they are.
While I commend your enthusiasm, I am a metal fabricator that does build in aluminum, and engineer that, after doing our regular HVAC design, and custom ductwork fabrication, among other things, does operate and repair DOT inspected trailers, so....I think I may have some liability perspective, here. I've actually talked to insurance people about trailer manufacture and repair (and performed repairs). This is a large area for potential litigation. I have that risk when I work on trailers, even though I have welders certified against my AWS and ASMEIX welding procedures for processing carbon steel, aluminum, and a variety of stainless and Nickel alloys.
I know, for instance, that if you attempt to weld an aluminum trailer without knowing what you are doing, you can have fatigue failure problems at the welds. These can be caused by lack of heat treatment, poor welding, bad electrode selection, poor metal selection, and just bad practice. Most aluminum trailers are bolted after forming, and that is because the welding is very difficult. If you would like, talk to a couple of aerospace guys about welding aluminum wings. I expect they will tell you that is a bad idea.
If you build a trailer, and it is properly ID'd and tagged, when there is a deficiency in an accident, the manufacturer WILL be involved in any lawsuit. If you are the manufacturer AND the driver/hauler, you will be sued in spades if you made bad decisions, or at least decisions that aren't best manufacturing practice. Blaming the guy that sold you brakes will not absolve you.
As I said before, I'd suggest talking to your insurance representative and tell them that 1) you will be building a trailer for over the road service, and 2) it will be a welded aluminum trailer. If you deliberately mislead the insurer for short-term approval, you may have trouble 'down the road' so to speak.
If you choose to not take my advice, that's fine. But I have had experience with the legal system in the US, and I think that you are optimistic.
There's enough potential liability that I am uncomfortable telling you how to do it right, because, as a professional with expertise in this area, I could inherit some liability, simply by doing so.
If you want a deep dive into this, I can help you navigate, but this is an area I have had no desire to accept any further liability.