I have often thought that we are now getting near to a situation where you cannot build a decent trailer as cheap as you can buy one if all the materials are new. Another option is buying a large trailer cheaply and breaking or modifying it.
bgy the time you have got the running gear, lights hitch etc you can get a used one and modify to suit. don't forget the 750KG rule for unbreakable trailers only stands IF the vehical is capable of 750KG towing. had to take the works trailer for a re plate last week as the transit at work can only tow 500KG! braked or unbaked
5mm sounds thick. My 750kg trailer (6' long x 3' wide 4' high box plus draw bar) weighs in at 160kg inc the high sided frame, rear door & tarp. The metal is more like 2mm for the main frame & less for the sides. You need to use the shape, design & form to make it strong not more metal.
I built a trailer a around 18 months ago, which I proved could take 1100kg of sand on it's first trip. I thought the car was struggling...
It was built out of 65x35 box, plywood sides and tray, with a 20mm pipe rail along the top and plenty of tiedown hooks, and a fold up jockey wheel on the front.
When I had finished it, I figured out I could have bought a new galv one for less than the materials cost. It is amazing how all the bits add up - there must have been a couple of hundred dollars (NZ) for the cold galv paint, etch primer and metal enamel top paint.
Geoff