An aluminum automobile safety frame has been the main feature of this extensive, basic research project. Earlier papers have covered the logistics of the whole, plus certain specialized results in the mathematical background. This paper describes the problems of design and construction of the lightweight frame structure for a research vehicle. Parameters of alloy selection, central strength, potential impact absorption, and frame junction methods are emphasized. Also discussed are future modifications to carry forward basic research to lead to eventual mass production planning. Conclusions point to the enhanced prospects for the future of greater safety in energy efficient automobiles.