[O'Sancheski]

Answers are in bold.

A few questions:
-What size rivets are they, and at what spacing?
3/16" at 1/2" spacing
-Why the 0.090" 5052? We looked at 5052 this year, but decided to go with 0.063" 6061 (and later decided we should have gone with 0.050" 6061). A thinner material would be lighter, and 6061 0.063" is strong enough for a FIRST robot with bumpers.
I decided on .09" 5052 because that's what I've seen many teams use and since it was my first sheetmetal chassis I thought that would be a good starting point.
-Any details on the shifter, specifically the ratio and shaft design?
The shaft is made custom on a lathe/mill. I will try to upload a pic of the actual shaft but it is not letting me put an attachment in this post.
And finally, any plan to remove the transmission in vehicle if you ever have to? It looks like it would be very, very difficult to work on anything inside the transmissions as it is now. Even though it would possibly weigh slightly more, you could pocket out the space of the transmission side plate that is integrated into the frame, and put another plate over it. The transmission would then be a single assembly bolted into a hole on the frame.
I am going to pocket out the flanges above the transmissions. I am also probably going to remove the rivets attaching the transmission to the chassis and replace them with bolts for easier removal.