It is not too difficult to build your own chassis. Laying out the metal (with
all the required ears) is the most demanding part. A shear is not necessary.
Cutting exactly is the most difficult part, but metal fab shops can cut it to
shape. Although I have a large metal brake, the $50 work quite well. For
boxes, I just saw up some surplus angle iron that is the proper length. To
finish the boxes, pop rivets can be used, although real rivets look much
better. A hand riveter will do most of the riveting required for a box.
Find a new friend who is building a metal airplane. Chances are they have all
the tools and will help you learn how to do it. Or, build an airplane to give
you the skill to build a box.
73, Colin K7FM
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