OK got her installed last night. Tolerances were spot on. Its REALLY rigid, so I can see this snapping pretty quickly with this material (even though this isn't meant for use). Aluminium will be better, but were taking away the purpose of this piece.
I am thinking the bend in the plastic was to act as a bumper, and this is why we keep breaking it. I'm not sure what you could put there and take the weight of a 1/5 scale with momentum and not break. Since we have removed the bumper, what is this thing going to now land on? the back of the chassis? I think making this one piece out of alum will just transfer the breakages to the curved top piece instead.
I would still buy one. Anyway, here is the pictures.
I am still interested in picking one up when you get them finished. There is a thread over on URC about a guy who went brushless and is having some issues with chassis flex. I think one of your cages would quickly put and end to any worry about that.
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