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Re: 80/20 chassis
Team 2228 has used 8020 from the start. We almost always stick with 1010. (We did go to 1020 for our 2008 lift). As for fastners, we have standardized on 1/4-20 wherever possible to reduce the need for more tap sizes and tools (DFM). With respect to fastners we mostly use the economy nuts. They are far cheaper than other 8020 alternatives and weigh less. You would be surprised how fast nuts can add up on weight. For the bolts stock up mostly on the shortest two sizes. While it is nice to have a few of the longer lengths in most cases you find these too long and the bolt bottoms in the 1010 extrusion prior to the head pulling whatever tight. We carefully tighten and have had very little problems with loosening. Be sure to properly clamp prior to drilling or sawing for safety.
We have no welding capability at this point and with 8020 I am not sure we will pursue that for some time.
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