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Re: Building the Structure of the Robot?
If you can get a welding sponsor welded tube is one of the easiest ways to go (at least for my team welding is faster than rivets and gussets). We have built robots on budgets of ~$2000-$3500 for everything (spares, prototyping, tools, and so on) using the tube. If you use 1" square 1/16" wall aluminum tubing you can build your robot structurally in much the same way you would with the extrusions but with a much lower weight and cost. Considering our machining resources usually are about the same as what you described transitioning to welded frames of thin-wall tube should be relatively easy (if you can get a welding sponsor, otherwise do gussets and rivets/bolts).
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7 Years of FRC
 "You students are at the top of the mountain, at the pinnacle of success, and what is it that you do?
You become the future guides to help others climb the mountain."
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