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Here's an idea:
Whil considering construction methods for an areo-trailer, pick up a copy of Harold Peyson's "Instant Boats", he has other titles as well.
A buddy of mine turned me on to Harold's approach about 15 years ago when I was thinking about building a duck boat. It's something he calls the "Stitch-n-glue method" of building boat hulls with little or no frame and no mold or buck. You build from flat sheets of luan door skin (super strong yet thin mahogany plywood available everywhere), epoxy and associated fillers from Westsystems (any West Marine store), and a little fiberglass cloth as an overlay. It's not the true compound curves you could get if building a foam plug, a mold, then a shell from fiberglass, but not nearly the investment in time or money, either.
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