Wolf, while I won’t condone the mods that Trailex is so CYA about, I must say that the photos you’ve posted of your various creations and mods make me wish I could hire you!
Just a cautionary note: I first owned a Triton Blizzard XT one-sled snowmobile trailer that the dealer modified to create a longer tongue. This was very easy for him, by just drilling another hole where the NESTED tongue tubes were held together. He pulled part of the inside tube out more and then bolted them (still nested) using the new hole. Because the aluminum tubes were each far, far thicker and larger in cross section than the Trailex tongue, it was safe to do so for hauling a light load. The trailer had a payload max of 1300 lbs, so I considered it good for up to 650 lbs—still much higher than two heavy plastic or glass sea kayaks and rack hardware totaled. We made crossbars from padded 2x4s and later changed that to use Yakima bars and towers, which were attached via some minor mods that I hired a welder to do on the low aluminum sidewalls.
I used that trailer frequently for 10 years before handpulling it up a steep dirt driveway and ramp into the storage shed got to be too much. That’s when I bought the Trailex, which weighs less than half as much. But I still miss the Torflex and ground clearance of the snowmobile trailer.
Right away, I noticed how much thinner the aluminum on the Trailex tongue was, in addition to being smaller in height and width of the cross section. Bigger than the limp-noodle tongue of the RacknRoll/Yakima trailer, but still wimpy relative to the snowmobile trailer’s tongue.
Bottom line: Be careful about overloading the Trailex. The warranty is only a temporary concern; the real worry is safety and durability.