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Re: What types of metal do you use for your robot in general?
In addition to KoP Chassis parts, we used Vex versaframe, 2x1x1/8" aluminum channel, and 1-1/4"x1-1/4"x1/8" channel this year.
You are less likely to crush tubes if you use blind rivets rather than bolts. You will need about twice as many, but they're much lighter than bolts and don't crush tubes.
The only place we usually use steel is where we do use bolts and nuts, a few shafts. chain, and internals of COTS items.
We made a few parts out of a rubbermaid garbage can this year. Not for structure, but it worked well keeping the cheval de frise out of our robot, and if we'd had a lot of trouble running over boulders, we had figured out a flap on the front made of rubbermaid to push boulders away but allowing us to use the wedge for climbing over obstacles.
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