pic: WCD Sheet Metal Hybrid

[roystur44]

Cory,

How about slotting the top of the 1 x 2 tubes so the bearing blocks drop in from the top. Once tighten the bearing block becomes integral to the frame and strengthens the tube. That would make your transmissions and wheels drop right in.

Using 6061 T-6 for your belly pan would be fine if then is no bends. Laser away.

There is a process called bump bending in which a series of small tangent bends along a radius which used to create a large radius bend in sheet metal. You can use that process to bend T6. T6 Sheet stock just requires a large inner radius or use of a wrapper while bending.

If you are worried about your front/back bending in you could attach a small hat section of sheet metal behind the front and back along the length. This also could serve to be the mounting rail for the manipulator. I think being able to mount and adjust the manipulator is very important in a design.

Here's another idea. How about making the front and back circular?



You have a good start.