[sdcantrell56]

Originally Posted by Alex Cormier

Take a quick look into my pictures for reference. I like to design chassis that anyone can build. This is easily built for teams in a wood shop with very basic tools.

Based on this comment why not looking into building the chassis from baltic birch plywood. It is even lighter than lexan and in my opinion much easier to machine and assemble. Simple wood glue and brads/screws and you can have a chassis built in a couple hours.