[Qbot2640]

Beyond the design, be aware that there is often a "sweet spot" in quantity of robot builders at the build site when you are working. You don't get much done with too few people...but you also get very little done with too many. With a small team last year, you didn't likely encounter this problem. But with a much larger team you could easily have days when new members come and either don't know what to do or don't have quite the same self-motivation as the core group from last year. We have found (the hard way, of course) that it is imperative to break the build into highly focused sub-teams and meet by sub-teams at different times or different locations. I would recommend creating those sub-teams during your design phase (or some, at least, before kickoff even).