pic: 3 Hour Chassis + 2 Hours

[548swimmer]

Originally Posted by Ty Tremblay

I intend to weld the cross beams to the inner plates. Our team has a CNC mill, but it doesn't have a coolant system built in, thus milling operations can be quite cumbersome. By designing it this way, the only CNC operation necessary is the drilling of the holes so everything lines up square. The rest of the dimensions are more or less non-critical and can be cut with some careful band sawing.

Could you use a smallish size end mill and cut like this:

______
|xxxxxx|
|xxxxxx|
|_____|

so the center piece falls out.

If you can use a 1/16 or 1/4 bit you can cut past the needed length/width just enough so that you end up with squared corners.