[Sachiel7]

This year (in a few weeks) we're going to prototype our frame with wood extrusion. The aluminum version will probably need welding... We need to find somebody w/ an aluminum welder, and who knows how to use it!
We're using 1.5" aluminum square extrusion (hollow) for the bulk of our frame. We're taking our drive/chassis design from last year and improving it. We'll probably plan on using it if there isn't anything weird about the game that makes us change our minds.
Anyway, I'm actually making a frame that uses crossbars. My first time actually paying strict attention to structural integrity and force transfer. It's really not that hard once you get used to it.
We're also probably using 6601 sheet for our flatbeds.
I'm getting everything from onlinemetals.com, BTW. Just in case anyone's interested. You can estimate your cost and weight from their info.
Oh, and the frame I've got without any drive or electronic components should weight less than 18 lbs.