[daltore]

Hey, team 2158 is doing the same summer project! To cut down on weight and price, we're making our modules out of 3/8" Lexan, if it helps at all. Aluminum should be comparable to both price and weight, though, so stick with what you're team is comfortable doing. You're right, the main expense is coming from the 90* gearbox. We haven't really been able to find a way around that other than building a custom one, but since we don't have any machining tools, that would end up being much less stable. If you feel confident enough, you could find some set-screw-on bevel gears and align them yourself, which should save you quite a bit of money. Good luck!