I suspect a lot of your questions would be answered by the riobots manual (google it). The guys that built minotaur in the US put a lengthy manual together to help people get into bot building. A lot of it will be international in terms of components etc but it should give you a good handle on the basics. I've never read it cover to cover but have skimmed it.
As far as your first machine, if you plan to build a basic lifter with a drive train, which is a good starting point, then I'd probably go with the box section frame welded up with paneling bolted on. The modern way to build bots is to get a monocoque laser cut and then welded together but putting together a CAD design for such a machine requires a good bit of knowledge to get it right. A box section chassis allows you to easily add and remove things as you go along.
As far as scavenging goes, you might get lucky and stumble across hardox in it's professional form in a digger bucket or truck body being used for what it was designed for, a wearplate application. Either way steel in those uses is likely to be higher grade although it will probably be on the thick side.
The two main issues you'll come across in building bots is weight and money. There is never enough of either to do exactly what you want to do.
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