Having built the chassis in CAD in 3 different ways, I found out that the easiest and fastest way (for me at least) was to use the dimensions from the 'jig' template. That was my 2nd try...
The first try was making each tube by itself and then making the assembly, then I had to trim or extend a few pieces in order to fit.. at that point, I thought that the dimensions of the real part should be slightly shorter than 100% fit in order to be properly welded and I stopped..
The 3rd try was calculating midpoints and making a weldment assembly.. was the most difficult way to do it.. but after that, you can change material profiles very easily, and make stress analysis even easier.. !!
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