[IndySam]

Originally Posted by Chris is me

Rivets and gussets are definitely both rigid and adequately strong for this application. I don't understand where you're getting rivets with enough play that you can't hold a frame together with them.

We used overly thick 1/8" gussets and a 1/16" solid belly pan this year instead of welding. Chassis was just as rigid, really. No noticeable performance or strength difference at all. Welding is not mandatory for this kind of drive. And there is definitely no need to do *both* permanently.

Here's a picture of our setup. The thickness of the gusset and the number of rivets used were both excessive, but rivets are almost "free" in terms of weight.

Add a good epoxy like Locktite Hysol and those riveted gussets can be just as strong as a welded joint but still removable with a drill and some heat.