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Sounds like you're on the right path. I'll mention it, just in case, but IMO, one of the most important measurements to get right, when "cloning" a chair spec between brands/manufacturers, is the distance between the front of the back rest and the front of the footrest. (Other than the obvious...
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Ok. I will make an exception and approve your survey post. It will show up below this sticky Topic in the Survey sub forum.
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Oh, I don't know about aluminum, as far as thickness is concerned. I was referring to the carbon fiber sheet I've (and others) have been using as a lighter, stronger, alternative. 2.5-3.0mm is good for that IMO. That might be a bit thick for metal. I'd see what the welder seems to think would hold...
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Aluminum seat pans are a relatively common option. They have been known to sag a bit over time. Carbon fiber sheets are also used. That's what I went to on my TiLite Z chair. I used sheets from Arris, that I found on Amazon, to cut both seat pan and side guards out of. The seat pan only needed a...
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I don't do any of it, but man, I sure do like RC stuff from afar. Seems like likes of fun.
(I remember waaaaay back, early 80s, when OldGrumpyDad and I were kids, like 12 or 13, both our sets of parents (unbeknownst to them) bought us the same RC car, from Radio Shack, as one of our Xmas...
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I tried doing the SCI group thing, but didn't find much locally. A couple very cool cats running the local basketball team, and PVA's regional handcycle race team, but over all I encountered folks who didn't seem (or act) very happy, or terribly nice, and definitely not much fun to be around or share...
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