[John Simons]

I think that you have an excellent idea with useing a steel frame, as long as you select the proper grade. Our team has been using a 4130 chromoly frame for the past few years and it has worked extremely well for us. First of all, it has a much higher modulus of elasticity than aluminum and therefore will deflect less in an impact let's face it that just tends to happen in these games. Secondly, it's fairly lightweight. I know that you thinking this probably can't be true, but it is. One inch square tubing with a 0.049" wall thickness is only about 18% heavier than 1" sq. aluminum tubing with a 0.125" wall thickness and has about 3 times the strength. Third, this will allow you to weld more easily. It can be welded with a standard MIG, although I do recommend TIG. Or if you're in a pinch or have electronics mounted on the frame it can easily be gas welded. If you want a real world example of where this material is used look no further than autoracing. Most roll cages are built out of this strong material and some vehicle frame are built with nothing but.

If you do decide to use this material you will have to do at least two things to ensure the longevity of the frame. Firstly, you have to paint or clear coat it because 4130 is highly susceptible to corrosion. And secondly I would recommend annealing the frame to reduce stresses that may have been introduced during welding.