Well I guess I better get in on this upgraded chassis then....Heck...why not...already spent way too much time and money on this stupid thing...might as well make it an obsession!
If someone can e-mail the dimensions of the chassis and all the holes...I can draw something up I think would work. I'm thinking of a chassis with a built up backbone and ribs..kind of like this picture of a random piece I found on google images...with the addition of a backbone of course.
Instead of using sheet aluminum...use plate aluminum and then machine down to expose the ribs and backbone. THEN..when all the machining is done bend the 30 degree front lip.
I can do a 3D drawing for Dr.Honda's machines, plus a flat template for cutting...and a blueprint for Dr.Honda to work from if he wants it.
With a 1/4" BullNose it would take maybe 15 mins of machine run time. 1/4" cut the pockets, tool change and drill holes, tool change and countersink all the holes, bend the front...done.
If we are going to make a custom chassis...lets make it STUPID strong.