[ajlapp]

we weld this type of frame all the time.......

using the 45 degree angles is a good idea.....if you have the time making a jig and standarizing sections really saves time and makes things more uniform.

if you can design the frame around a few uniform sections then there will be less variation in your final dimensions.

do carefully consider your tolerances though. don't count on your dimensions being exact, welding can produce lots of variant, especially when welding aluminum, and especially when your welder doesn't know the deisgn and doesn't take their time.

good luck and take a look at wildstang's robot from last year, they used a square tube frame very effectively.