we just built a prototype chassis for offseason (yes it was sheet-metal). And we used lexan in the middle for the electrical board. Lexan is a great way to strengthen the chassis (even though i dont think we needed it). I would recommend rivets, as we just used them for the first time and they seem to be very strong.
Why are you using an omni wheel? Is the center wheel lowered? How thick are the spaces between the lightening holes?
Cool Chassis though
