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[Gaffers]

Looking at the condition of the rest of the trailer I may have to rebuild it completely.  Some of the cross members are rusted beyond repair.

[Marks DTM Calib]

Nothing some nice steel and electric glue wont fix.

[Martian]

Nothing some nice steel and electric glue wont fix.

"No nails" and cable ties work for us when we have a fixing that won't stay put 

[Gaffers]

Nothing some nice steel and electric glue wont fix.

I'm too-ing and fro-ing between repair and rebuild

My biggest question would be how to make or acquire the box section to make the cut and shunt for the axle and how long should it be? 50% of the axle length?

[Kevin Wood]

Nothing some nice steel and electric glue wont fix.

I'm too-ing and fro-ing between repair and rebuild

My biggest question would be how to make or acquire the box section to make the cut and shunt for the axle and how long should it be? 50% of the axle length?

Would it even need to be sleeved? Just but the ends together and weld? If the weld is done competently it will be OK.

[Martian]

I'm too-ing and fro-ing between repair and rebuild

My biggest question would be how to make or acquire the box section to make the cut and shunt for the axle and how long should it be? 50% of the axle length?

Pop round for a chat sometime M, my mate is still at the place that kindly donated the chassis parts for Triketon and can source that for you no problem.
In fact, throw in a crate of kangaroo piss for me and a couple of demijohns of homebrew for him and we'll build it in my garage for you 

[Gaffers]

I'm too-ing and fro-ing between repair and rebuild

My biggest question would be how to make or acquire the box section to make the cut and shunt for the axle and how long should it be? 50% of the axle length?

Pop round for a chat sometime M, my mate is still at the place that kindly donated the chassis parts for Triketon and can source that for you no problem.
In fact, throw in a crate of kangaroo piss for me and a couple of demijohns of homebrew for him and we'll build it in my garage for you 

Thats a kind offer, worthy of more than just a bit of beer.  I will likely take you up on that offer

[bigegg]

I'd be tempted [1] to ebay the extra wide axle and use the money to buy an axle of the correct width.

Alternatively - I've made, and over-engineered, a few trailers - some braked, some unbraked -
I always make them LOOK competently made, and never had a problem, either from plod, or from a safety point of view.
And I'd only call myself an amateur "stick" welder.
so my 2nd recommendation is just "go for it"

[1] only just returned to the forum, so may have missed some of the story...