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Aluminium is ok if it is thick enough, but Meggamouse didn't like the constant hitting it was getting in Aus from Thor. But then you don't fight Thor 4 times a day and have to let him hit you.
Would like to change but 4mm Hardox will not be sturdy enough, and it would be cheaper to make a new bot.
Make the robot fast and agile and good driving will keep you out of trouble, look at Beast...
Trev
Beast (and Beauty for that matter) are good examples of lightly armoured and well driven
I have to make mine like a tank which is more about my driving than anything :)
Trev - you said 4mm Hardox will not be sturdy enough. Is the Al much thicker? Interested in the comment.
It's not only thickness that counts. Tough As Nails demonstrates that rather well, 12 years with the same3.2mm Hardox 450 armor/frame.
Flexibility and shape are other factors.
Also, dents and other battlescars ain't a problem, unless those are interfering with the rest of the function.
Better to have dented armor than rattled electronics.
Beast and beauty's don't do armour
Exactly, the closest I have got to a Beauty is the tip of the flipper arm :D Enough said!