For the chassis of my new larger robot I chose to use MakerBeam which is a fantastic product construction kit designed for prototyping and building models (like meccano for adults!) – it consists of aluminium beams and various different fixings to allow you to easily build just about anything – it is also very strong and lightweight so ideal for my robot chassis
For UK readers I highly recommend Technobots as a supplier for MakerBeam
For the base of the chassis I chose some perforated metal sheets – again purchased from Technobots – as the holes would be perfect for mounting the Pi and all other electronics