[OccamzRazor]

If you make a lot of design changes then welding is not the way to go. We specifically chose not to weld anything on our robot this year in case we fell from the tower. We did once during build season week 5 and the robot fell 5 feet to the floor (everything was ok!). If you break a weld at competition there is almost nothing you can do and because FIRST Stronghold was such a rough game we made that call early and went with rivets. We had a few shear during one impact on the field but as long as you use enough gussets and use the right diameter rivet for the application they will hold up just fine. They are super easy to replace and you can add more if something fails.

Now we do weld certain joints together on our robot if the assembly is modular and can be removed and replaced. It does make a superb joint if it is welded correctly. Welding joints can save a lot of weight and reduce fabrication time for some systems. If you have the capability then definitely use it. Try building a test frame and drive the wheels off of it.