I was already beat to the punch on tool use; yes, there are schools that have limits, either procedural or simply for lack of them. So I'll add in another constraint to consider: purchasing.
Not all schools or institutions have FRC-friendly procurement rules; some refuse to let someone go out-of-pocket and get reimbursed, others can only write purchase orders that not all merchants accept, and still others will be glad to cut you a check--Monday mornings between 9:15 and 9:45 AM, for an exact documented amount,
if the hand of the bookkeeper that signs such checks hasn't cramped up. (Trust me, I have some
interesting state purchasing tales.)
If you can cut the number of suppliers down to one or two, the odds of that bookkeeper's hand cramping up is lessened.
For 2008, a team with a firm grasp of physics could build an effective (wide-track, for the sake of argument) 2WD robot with one hacksaw, one drill and bit (to enlarge the axle hole to 1/2"), one allen key, one wrench, and four 1/2" nuts and bolts. Even if nobody on the team had them to loan, you could pass the hat around and buy all of that for $100 at any hardware store in the country. (International teams might have more trouble; someone from abroad want to comment on how the IFI frame went together for your team?)
Also worth considering, for the folks talking about hacksaw-and-drill approaches, is the risk of That Freshman. (Not all freshmen, mind you, just That Freshman. You know the one.) If your material of choice is available cheaply in big huge sheets, you're probably fine. If That Freshman's mis-angled drilling is going to run a team $20 each time, it's a factor. (And, of course, remember that the kit frame's materials are there for free, whether used for their original purpose or some other; teams may also be able to wheel and deal for more of it from other teams.)
If you
still think you can beat the kit frame of past or near-future for the above (and let's not forget enough durability to last the season), I'm much interested in seeing.