[Jon Stratis]

The proper tool for the proper job.

In some cases, we tap material for the bolts. Generally, this happens when we have thicker material or are using smaller bolts (with closer thread spacing).

In other cases, we use a PEM nut. You have to be careful with these, as they are designed to work with a specific material thickness. If your material is too thick, you won't get a very good grip with them, and they can then cause problems down the road.

In yet other cases, we'll use rivet nuts. These are great for working in the robot frame, where it's generally difficult to get a wrench in there to hold a nut.

Finally, we'll use Nylocks. We much prefer to use a locking nut than a normal one, given how much the robot moves and shakes... we don't want to have to tighten the bolts between every match!

We also use pop rivets. A lot. Generally speaking, major frame parts are bolted together, as are parts designed to be separated. When putting in gussets, shielding, and such we use pop rivets. You don't have to worry about them coming apart (unless used inappropriately), and yet it's pretty easy to take them out with a drill if you need to.

So in short, get a tap set, get some different types of fasteners, and experiment. Even if you decide one type of fastener isn't really useful for your team, everyone will have gained some great experience and knowledge!