Rivnuts come in all different configerations and you possibly need thin sheet one's MikeB.
The question of weakenig the chassis is a good one,normally if something splits or cracks the fix/cure is to drill a small hole at the end of it,so I would think that unless you can drill a square hole you should have no problems and with square tube you have three other sides to support it.
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Cost : Little as possible.
Thanks : To those who by their generosity my build has progressed.
Its a handmade sports car not a flaming kit car !!!
If at first you dont succeed,avoid skydiving...
No parachute require to freefall,only if you want to do it twice.
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