A "normal" batterydrill drive uses a 3/8 UNF nut on the shaft thread, and an M5 left bolt in the hole. The bigger batterydrills use sleightly larger threads, but those I never had to use (helped Ellis with 1 tough).
EC and XT connectors can be bolted , with a well drilled 3mm hole.
For structural HDPE, with good connecting methodes and well used bracing, 5mm could do.
Decent spinners will rip trough, but with enough airgat between armor and vurnable parts, that's no problem.
Team RCC's feathers use a T frame. A steel backbone where all the parts are mounted on, and the armor is "draped" over that. Is that Hardox or HDPE, nothing enough bolts can solve.
Why steel? Ali wasn't the best option, as Hannibalito 4 has proven, and titanium in that shape is way beyond our wallet.
If stiffness is an issue, and weight so you would have to use 4mm or thinner ali, you always can look to glassfiber filled nylon.
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