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Re: Chassis Connections
My team has used bolt-together frames, typically plywood with angle-aluminum brackets or the kit frame. For 2010 we welded the kit frame together (saves several pounds of weight over fasteners) with some custom wheel brackets. Took 1 mentor (me) less than two hours to do at work (we had no welder at our work space). We then bolted on everything else, including some 3/8" plywood for a deck.
I would highly recommend welding the kit-frame together for the weight lost and stiffness/strength gained. It's 5052 aluminum, so it has no temper to lose through welding. If you are just welding the kit frame together it should take less than 1 hour to assemble, prep, and weld. The kit hardware holds it in place very nicely.
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Theory is a nice place, I'd like to go there one day, I hear everything works there.
Maturity is knowing you were an idiot, common sense is trying to not be an idiot, wisdom is knowing that you will still be an idiot.
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this is robotics--everything is going to go wrong at some point, it's how we deal with it that counts - abigailthefox [more] 
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