Another method you could consider for axles is to use a 3/8" bolt that goes through a 1/2" OD tube. This lets you put the wheel in with its spacers already in place and also doubles as another standoff. We used this method after all of the trouble we went through adding spacers when changing a wheel on our rookie robot (using 1/2" bolts as axles).
I would also echo what Nuttyman said... the lack of diagonal bracing is a little worrysome. You could use corner gussets or perhaps a bellypan to reinforce the frame. I prefer bellypans since they provide a ton of diagonal bracing and also serve as an electronics mounting surface. In 2007, we had a 1/16" aluminum bellypan (weighed about 5 lbs) and it worked great.
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Originally Posted by JHSmentor
for the lightening holes - there is no guarantee that we will be able to get these cut out but I wanted some opinions just in case. I also have not figured out how to get Autodesk to calculate weight so I have not compared it with and without the holes to see the savings. I would think that 4-5lbs would be a good savings but if it weakens the frame too much then it's really not worth it. Again, I don't have any practical experience with this to know.
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The frame will probably be fine with those lightening holes if you're using bumpers. If you're using inventor, you can set the material and measure the weight of a piece by right-clicking on its title in parts tree and selecting "iproperties". Under the "physical" tab you can select a material and it will tell you the part's weight (or you can manually set a weight if you choose). In an assembly, you can click the update button on the "physical" tab and it will give you an estimate for the entire assembly.