Building the Structure of the Robot?

[ksafin]

Hello all.

I believe many beginner teams (including us) use aluminum extrusion such as 80/20 or T-Slots, as it's very simple to use, intuitive, and cost effective.

However, as we progress throughout our FIRST life, we're seeing more and more cons to extrusion.

Extrusion is considerably heavy in comparison to alternatives such as custom machined lightweight aluminum.

It's also not nearly as flexible for construction, given it's only a straight 1"x1" rod really.

My question to you all is, how would you suggest/think (or if you've personally started by using 80/20) wane off the use of extrusion and transition onto more advanced structural materials?

To add to that, in what way can you accomplish this given low-moderate funding ($7,000/season), and pretty much no specialty tools (unless the tool in question is affordable). I'm saying we only have a Miter Saw, Drill Press, and Bench Grinder. Scroll Saw & Band Saw are not out of the question.

Thanks!