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Re: Welding
What about pop rivets? My team did that in '04, and we were able to assemble the entire bot with 2 rivets on each corner (out of angle/flat stock aluminium).
The advantage to that, is pop rivets are simple to use, are very light, and are a great pre-work for welding in case you find a good welding shop to help you out.
Just Note: Most people you meet will not be able to do Al welding, so find an automotive shop to help you. If you can find a performance automotive shop, they will almost always have aluminum welders and skills.
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