This topic is right up our teams alley. Check out
www.huntingtonrobotics.org for our photos on our past robots.
We build our bots from .040" prepainted aluminum sheet using a technique called Monocoque. We will be releasing a video (most likely after the build season) showing our methods of construction so everyone can gain from our experience. Our robots are traditionally light weight and very durable as seen in videos of past regionals. We form the material to provide the outer shape and then use internal bulkheads to support the outer shell to provide the necessary strength of the members. We use the thin material so we can bend it with hand tools and it is alot less expensive than than the thicker materials and it still provides plenty of strength for what we need to do.
Feel free to send any questions our way, we will try to answer all questions that you may have.
Curt