Has any team or anybody made a 80% - 100% lexan bot?

[Gdeaver]

Team 104 has used polycarbonate for a frame covering the last 3 years. We use 1/8" and 3/16" 6061-T6011 aluminum 1" angle for the frame joined with steel pop-rivets and backup washers. The polycarbonate is held on with 1" velcro. Mcmaster Carr sells velcro with a very strong contact adhesive. We have a sign shop make our decals to be applied on the inside. The inside of each panel is then painted. Our decals and paint can't scrape off. Note- make sure the paint is for lex an. Most paints do not stick. We have not experienced any frame damage or panel damage.
Polycarbonate is expensive. As was noted in another post, birch furniture grade plywood is very strong and light. To take it up another notch in rigidity and strength, Try laminating 5mm, 3/16 or 1/4" plywood with 1 or 2 layers of 4 oz. s2 fiberglass and epoxy. It's an excellent structural material and is fairly cheap. With our budget constraints this year we may have to use it.