Whilst I wholeheartedly agree with all comments so far made I'm still going to throw a funny shaped ball into the park. I'm rebuilding an existing car, not a Haynes or Locost I hasten to add. I'm using the Haynes book for inspiration and general ideas but while my finished car will hopefully look something like the Hanyes there are going to be major differences. My wishbones for example will be quite different in dimensions than the Haynes, my chassis is made from a mixture of 80X40X3, 60X40X3, 25X25X3 box and 25X25X3 angle. Although a lot of the dimensions are going to be similar a lot are going to be quite different. I still wouldn't go for round tube for the main chassis structure though. If you want to build a Haynes then go by the book, if you want to build something else then fine but you need to be pretty sure of your own abilities. The point about CAD design and stress assessment is a good one and not to be ignored lightly.
D.
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