I was on the beach this weekend dreaming about chassis'. I don't think it would be practical for the numbers here, but to make this chassis available to the masses. This process might come in handy:
http://www.yamaha-motor.co.jp/global...nnovation.html
If you already have the files in Solidworks it seems as if it would only be a couple clicks away for a mold???? But then again I haven't gotten to that area of Solidworks yet.