well block of wood is probably one of the most known fw wooden robots, we use bolts to bolt the sides to the base plate then screw the top on

base is 25mm thick
top is 25mm thick
walls are 50mm thick

it offers good enough protection and is easy to machine etc.

still got the damage on it from hornet

also i would really recommend a crusher for the linear actuator, again i have built one and it does take alot of attempts and working things out but its all good

when soldering cells dont heat them up to much

the power pole just put solder in the tube part of the metal piece then heat it up and push the wire in
then when this is COLD push into the anderson plastic bit get it the right way round otherwise you won't get it in

hope this helps
alex