A few years ago I visited the Tesla Showroom , when it was in Menlo Park, next to Palo Alto.
They had a rolling chassis sitting on the Showroom Floor ( just lower part of the car with wheels , cut away to show where the batteries and motor go. etc.
Looking closely I noticed that there were few, if any , welds, If I remember right there were No .. welds , it looked like one part was inserted to another part then glued/bonded to each other.
I asked the salesperson about this and he confirmed that the chassis was indeed bonded together.
You do not , have , to learn welding. Bonding ( with a few bolts for added piece of mind , make them aircraft bolts ) could and even should work better .
Vertigo wrote:If nothing else from this project, I learned that there is a reason most bike frames are welded structural tubes. All of the 20 or so water jet cut parts had to have their mating surfaces machined flat and drilled and tapped to match. I spent the better part of a month staying a couple of hours after work each day to finish the machining. It also takes a lot more effort to make a stiff frame when you are working with flat plate as opposed to tube. So, to answer your question, I would not want to go into production with this style frame. It's cool because it's easy to change or modify something, but it was a lot of extra effort that could have been spent actually learning to weld!