Re: Pan chassis?
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I agree with defor no lexan or lucite or plexiglass. At radioshack you can get pretty large(for bits) pieces of fiberglass. It has holes drilled in it too so its easy to cut and wil be pretty light.
Have either of you thought about making the chassis out of sheet metal? I used to race 1/24th scale slot cars. I got into buying 1/24th scale models and making custom chassis to fit the bodies. Basically I bought 2 chassis and hacked them and soldered them together. It worked really well.
The big problem is it wouldbe full custom not a chop and slop. But the bonus would be motor placement. Like slot cars you could solder the motor to the chassis. Then you would only have to worry about exact placement of the axle and Idler/stepdown(gear between axle and pinion) gear. Also I think the steering area would have to remain plastic, to not affect the magnetic action.
Defor I love your original idea of having chassis stamped or photoetched. If you have a good enough design, I would be very interested partnering to get that off the ground. Drop me an email if you would like to discuss this further: nosajklr@hotmail.com