[Mark Pettit]

What's the difference between purchasing/stocking up on things like extra PWM cables, servos, keyed rod, wheels, etc. and cutting a piece of metal you intend to use for your 2005 robot?
In any case, you're taking the risk of not being able to use any of the stuff you're preparing based on the not-yet-released 2005 rules.
Similarly, what if you manufacture a robot base (or at least cut pieces for it) to the "standard" 30" x 36" dimensions only to find out that the "standards" have changed for 2005?
Let them (us) cut and suffer the possibility of a consequent rule change that renders the piece(s) useless.