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I am also worried about the combined flimsiness of parts/components. I genuinely think you should try to develop the most aero, lightweight trailer known to man
If thin rods are too flimsy and I swap them for thicker ones, I think the rack would still be much, much lighter than the lightest trailer.
At first I though this thread was madness, but now I understand it.
Since you are ready to mod bike, build rack and have bags made I take it you are invested in making it happen.
But as someone else have suggested I am also worried about the combined flimsiness of parts/components.
I genuinely think you should try to develop the most aero, lightweight trailer known to man. I imagine it being made completely out of carbon like those ultra lightweight aero cars that go several hundred km on a single liter of petrol. the one in the attached photo did 665km on a single liter.
Advantages would be:
So you have cat and you one the bike, and everything else in the trailer.
Another option is to make frame and bottom of trailer in carbon and then use a light weight fabric to cover it.
I genuinely hope you’re feeling better.