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Originally Posted by Stu Bloom
We're thinking of using it for the competition. It is VERY well designed and the cross sections/channel provides a good amount of stiffness, along with the relatively light weight. Some additional strengthening might be in order - our current thought is to replace the fasteners with welding after we finalize the configuration.
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Welding may be more complicated. As I read the specs for the frame material it is 5052 alloy of aluminum in the half hard state designated by the H34 designator. 5052 is weldable but tends to cracking on cooling. The aluminum once welded needs to be heat treated to relieve internal stresses induced by the weld and this is a complex process. If you have it welded by pros they will know what to do and should inform you of this.
You might look into some heavy duty aircraft style rivets as they can be quite strong, lighter than bolts and not subject to the complexity of welding this alloy.
I know there are probably teams out there that have welded frames in the past but it is usually 6061 alloy and not so subject to the cracking problem. Just a few thoughts and best wishes for the competition! LRU.
That sound you hear is a student on the mechanical team trying to get out of the shipping crate you closed too early. - Al Skierkiewicz [more] 
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