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My plan is to build a "methods and materials" trailer this winter to prove out things. It will be beetle-sized.
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So you're going to build a 5th wheel foamie to pull behind you '03 Beetle? That's awesome. I've seen Youtube videos of two custom 5th wheels that pivot in the center of an older Beetle (like the one from the 60s), but none on a New Beetle.
This 2" foam is going to be skinned with fiberglass isn't it? Maybe you could drill holes in the foam and put wood dowels or metal Z-straps in them to tie the two skins together.