[Al Skierkiewicz]

Nate,
As stated above the sizing box is a physical limit on size. Inspectors have no options on this critical issue. Weight and size are the first things checked during the inspection process, followed by bumpers. If you would like to PM me, I could offer some suggestions depending on what material your structure is assembled from and what the hardware is used for. As you can see, many of the experienced teams, build to specified dimension less at least 1/4" as two objects cannot occupy the same space at the same time (robot and sizing box wall). If you are using tubing, it is a simple matter of drilling a larger hole in the outside of the tube and moving the bolt head to the inside. If your bolts are used for mounting sheet material (aluminum or lexan) you may be able to use rivets and stay within the dimensions. Or you may be able to move the sheet to the inside of the frame. It is better to take care of this before ship, instead of during inspection.