Can I share a secret?
We have used the ITEM brand aluminum extrusion for the past two years and have had awesome results. ITEM's is stronger than other brands of the same size (Bosch, and others)--we had a 200 lb student stand and bounce on our box frame (frame stood on long end) and it only flexed a bit. It didn't break or permanently deform. See the attached pictures!
This year, the ITEM company is selling kits of extrusion and fasteners at drastically reduced prices for FIRST teams. Go to:
www.itemamerica.com and click on the FIRST link at the bottom of the home page.
All you need to use this structural material is a standard wood chop saw (miter saw preferred) with a carbide blade and a few allen wrenches. It cuts and machines easily for modification and is a breeze to assemble. Be sure to use cutting fluid on the blade.
The best part is that you can change the dimensions of your drive train or chassis in MINUTES, not DAYS when machining stock aluminum or welding.
We have already ordered kits for 2 of our rookie teams because it really does save time!