Dealing with the 25mm/1" discrepancy

[mr henderson]

The book assumes the chassis to be mainly constructed with 25mm square tube, but I daresay many of us are using the more common 1" square tube, which is approximately 25.5mm square.

This means that some of the finished dimensions will be out, for instance, if the main cross pieces BR11 and BR12 are cut to 1068 as in the book, then the overall width of the chassis will be 1068 plus 50 if using metric steel, and 1068 plus 51 if using imperial (1" sq), so 1mm wider.

Just wondering what those who have already constructed chassis using 1" sq have done about this? My inclination is to ignore it and stick to the book lengths, as long as everything is square I can't see an extra 1mm being a problem, but I'm always interested to know of other people's experiences.