Does anyone with experience before 2005 know if we should also connect the angled wheel guards with something like a 1" strip of 1/8" sheet aluminum?
Jessek my first season was 2004. I would certainly connect the wheel guards, while this adds weight to the robot it protects the wheels from getting hit with the corners of things such as other robots, bins and restricts objects from getting into the wheels that may be hazards such as noodles, loose parts and mostly importantly human hands. Given the style of the game this year, you may be able to get away without it but I wouldn’t chance it. 1/8th is probably a bit thick you could probably get away with 1/16th of course that is all about what you have access to and are able to work with as well.
As another veteran of the pre-bumper days, you probably want to skin the outside of that drive train (at least the exposed metal parts) with thin Lexan/Delrin strips to have a smooth surface [strike]if[/strike] when you hit something.
Having the ends of aluminum tubing exposed like that will make it easier to get snagged on something as simple as an exposed bolt head on a partner robot.
Here’s a photo of a WCD from 254 in 2004:
http://www.chiefdelphi.com/media/img/8e7/8e79053d3e9847389608859e011a1f47_m.jpg](http://www.chiefdelphi.com/media/photos/17134)
