pic: Rastogi 8wd Iteration 1.2

[JamesCH95]

Originally Posted by 548swimmer

6061 T6 is crazy strong, and really expensive. Depending on where/how you guys machine you might look at a 50XX series alloy with a lower temper (T).

6061 T6 is not terribly strong or expensive, relative to other aluminum alloys, though it is certainly more expensive than 5052, but 5052-H38 has the same yield strength as 6061-T6. Also 50xx alloys don't have a "T" temper because they're not heat-treatable, they are cold-worked (strain hardened) and have an "H" temper. Sorry 548swimmer, I didn't want to flame you too bad your other information was spot on.

Take a careful look at what sort of strength you actually need. Do you mind if a few small areas yield a little bit? It's probably okay if they do. Do you have a target stiffness for the chassis? If you make it out of .09" 5052 you can achieve the same strength, with lower stiffness, and half the weight, by making it out of 0.045" 7075-T6, if you can fit the required bend radii. Sure 7075 is more expensive, but the higher cost will be offset by using less of it. Making your frame half the weight has to be worth a decent chunk of money and is definitely worth considering IMHO.