[Scott Kozutsky]

I'd go as much versaframe as possible and use the 1:1 drawing on paper-glue-drill press method of making any gussets that need to be different and accurate.

I'd also highly recommend getting either a scroll saw or a bandsaw to help make anything more custom/ irregular.

Try to CAD the robot before you build it to make sure that everything lines up before you build it (IMO, CAD is pointless unless you use it to design your robot. If you build before you CAD, there's no reason to CAD because it's not influencing anything).

I'd avoid tetrix because of the cost if possible. Same reason I'd use wood (it really does work well for most things).

The best robots in FIRST are rarely the ones that are crazy complex, try to make a simple robot within your means.