Construction materials

[Gdeaver]

I agree with the the aluminum angle and pop-rivets. The frame can be crafted with only hand tools. T6061-t6 aluminum is readily available and cost effective. Do not use 6063. Use steel pop-rivets with backup washers. We usually use 1 x 1 - 1/8" wall. We cover the sides and top with poly carbonate attached with velcro. Mcmaster Carr sells velcro with real good adhesive. The poly adds structural strength. Welding the aluminum frame up is probably a bad idea unless a team has professional resources. Welding removes the heat treatment from a area next to the weld and can induce stress in to the metal from the expansion and cooling. Few teams will have the resources to stress relieve and reheat treat the whole frame. If a weld breaks during competition its a big deal. Drilling out some pop-rivets and fixing a frame is much faster. We have taken some massive impacts and not had frame problems. Buy some double end drill bits for the pop rivet holes.