A couple tips on how to make this look good (that I may have picked up from 1318's robot, but I'm sure other teams have figured this out, too)
As soon as you get your parts, paint the gussets one team colour, paint the rivets your second team colour. For added effect, why not paint the structural parts in a contrasting colour? Black works, but so does something more neon.
THEN assemble.
It is zero effort, but it actually makes your robot look like you went out of your way to make it look nice.
I'm torn between admiring the simplicity and rigidity of the VEX system and whining "it wasn't like this in the OLD days... you actually had to have some skills to make a nice, sturdy, robot."
Jason