First pick a good alloy—grade 5 or 6 for a balance of strength and weldability. Then draw the frame as a series of rib‑reinforced tubes, keeping wall thickness just enough to carry the load but no thicker than you need. Use a honeycomb or truss pattern inside the tubes if you can. Heat‑treat it: a solution anneal then a stress‑relieve. That takes out the internal strain from machining. Machining has to be precise—every cut has to be straight, no burrs. Finally test a section under load; if it flexes, tighten the ribs or add a small gusset. Keep the parts in one heat‑cycle if possible, no back‑and‑forth. That’s how you keep titanium light and strong.

Sure thing, just keep the paint thin—no extra weight. A light blue will show up fine in a pressure chamber, but watch for any cracking or delamination when the frame flexes. Make sure the primer’s good and the topcoat’s rated for the pressure, or you’ll end up with a splash of paint that’s not worth the trouble. Keep it sharp, keep it strong.

Sounds good. I’ll keep an eye on the paint’s adhesion in the mock‑up, but if the frame passes the pressure test, we’ll have a sturdy, blue‑kissed skeleton ready to dive. Let me know when you hit the 100‑psi mark, and I’ll swing by if you need an extra pair of hands with the rig.

Sounds like a plan. Hit that 100‑psi, and if the blue stays bright, we’ve got a winner. Keep me posted.