[EricH]

I wouldn't make a drive frame out of 1"x1"x1/16". Period. Superstructure, you bet, if it won't see a lot of hits or needs to be light. See 330's 2006 shooter frame or 2007 ramp frames for an example.

Typical drive for the BeachBots is 1"x1.5"(or 2")x1/8" aluminum. Superstructure may be the same and/or (the last two years) 1"x1"x1/16".

Why you don't use thinwall is simple: It doesn't like holes. You can only put functional holes in if you want it to last. No speed holes here.