Thank to Ellis' brilliant suggestion of making it less tall I have made an entirely new CAD model:
It may well look exactly the same but in fact it is now only 60mm high and by down grading the motors from 775s to 550s I no longer need to have the gearbox sitting inside the wheels so the bulkheads don't have to have a massive 40mm square hole in them for the gearbox. By converting to metric it has also allowed be to slim down the bulkheads to 15mm rather than 3/4" and the fron bulk head has gone up from 1/4" to 10mm. All of this has saved tonnes of weight so all the Hardox has gone back to 6mm and it still had the 4mm HDPE around the outside for added protection though I may thicken this to maybe 10mm. Depending on the wall thickness of the drum there can be just enough weight for a 4mm Hardox top and bottom, though they may need a few holes in them. For now I'll use 6mm polycarbonate and see how the weight is doing.
First job is to make the outer armour so I will send this off the waterjet cutters soon. One thing I am curious about is what do people think about the fron end? Are the little 'wedgelets' going to get bent up as soon as I hit a joint in the floor?
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