Quote:
Originally Posted by ksafin
Uh, we have access to neither of those.
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Do you have access to a hacksaw, metal file, and a drill?
Congratulations, you now have all the tools to make gussets the way 2815 does.
There's not a lot of magic to it; if you're worried, get a stick of 1" square tubing and a short (say, 2') length of 1/16"-wall, 1" angle aluminum. Make a box out of the tubing, riveting it with the angle used as gussets. Kick it around the shop a bit and observe its properties in the context of what a robot would encounter (usually with bumpers, remember). You'll be pleased, most likely.