[InFlight]

We have built entirely waterjeted sheet-metal robots.

A few requirements:
1) Full CAD of the entire robot,
2) a decent sized metal break
3 preferably a pneumatic riveter

Your CAD package should support sheet-metal parts. Make sure to set it up with your breaks bend radius, and decide what your standard flange size will be.

Temporally hold each assembly piece square before installing fasteners.

Make sure you have access provisions for any items that are inside the frame. Gearboxes, pneumatic components, etc.

Large metal breaks are not light or small. Our 48" brake weighs over 1200 lbs. You need a break large enough to bend an entire side of your 120 inch frame perimeter.

I would definitely try some practice structure before build season.