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Re: the frame
If you are using the FIRST design (and recommended) bumpers, then they do NOT fall under the robot sizing and weight constraints. However, they do have to follow (exactly) the dimensions and construction method spelled out in the manual. FIRST also limits the weight of the bumpers to 15lbs. Though, I don't think there was a single team last year that violated the weight rule, as the construction method can't really reach that weight.
Therefore, I would suggest cutting the kitbot frame down to 37"x27". This will give you an extra inch of clearance, in case you have bolt heads, gears, or whatever sticking out a little further than you expected.
Good Luck!
BEN
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