[Rick TYler]

Consider composite structures of plywood, epoxy and fiberglass, too. Like Gdeaver sez, you can accomplish a lot more than you might think buy building up composites rather than carving down blocks of solid material. I know most student robot builders are obsessed with aluminum and Lexan, but there a lot more materials around that can be superior in the right use.

As soon as you can, share exactly what you want to do and let us make more detailed suggestions. I've done a lot of woodworking and composite boat building using glass and epoxy (death to polyester resin...). I'd be glad to share what I've learned, but I need more to go on than you've described so far.

In any event, good luck on your project.