[IanW]

apalrd:
I have actually not looked at other widths of sheet metal, with or without lightening. As for the speed, I'm not sure where I would get gears to replace the final stage to get comfortable 6:1 and 15:1 ratios (Up from the current 9.4:1 and 24:1). McMaster's options seem to require more machining than I'd really like, so I'd appreciate suggestions.

Akash:
With the issue of the lightening holes, my team has not yet contacted possible sheet metal shops to inquire about a possible donation/sponsership, so I am unaware of their capabilities. And yes, the flanges are actually 1" wide, so I'll cut those down a bit in the next iteration. As for the bellypan, won't a 1/8" thick one be fairly heavy? I think I will add the 1/16" one I had back in though.

tim-tim:
I am trying to learn how to use SolidWorks' FEA tools, but unfortunately, I do not have a mentor that I can ask about it because none of them have any CAD training - I'm entirely self taught. If anyone here has some suggestions or tips about how to learn, I would happily give those a try.

Hawiian Cadder:
I think that this frame is already quite versatile, as the wide-open space in the bottom can accommodate either a manipulator or an electronics board. In addition, the pre-punched rivet holes provide ample opportunity to mount manipulators above the drivetrain entirely.

James:
The gearbox shaft is actually already supported in two locations, and from what I've heard, adding a third bearing is a bad idea. In addition, my team has cantilevered wheels off of toughbox and supershifter shafts every year now and never had any problems with it.

Finally, I'd like to re-ask my question about hemming: do other teams that use sheet metal hem their exposed edges in the interest of safety? Is cutting your hand open once the pieces are on the robot even a concern, especially with sheet metal of this thickness and chamfers on corners?

Thanks for the responses, criticism, and compliments.