After reading a bit more about the safety of mild steel relative to chromoly, I'm beginning to believe its not worth saving 25lbs to go to 4130 for the main cage. So at this point 1.625" X .125" 1020 DOM seems like the road to take. Easier to weld, cheaper, safer, more interior room. Good enough for me.
"Remember that cages mean to prevent intrusion. When your brain hits your skull in a 45g collision it won't matter that your cage was super rigid, you'll just be a well preserved corpse with jelly for internal organs. Energy absorbtion is the name of the game.While AISI 4130 steel typically has a higher tensile strength that is only a part of the picture. All steels have a very similar stiffness (modulus of elasticity) and Mild steel (AISI 1020 for this example) will deform 600% more before fracture than Chromoly.
(My reference is the ASM International Metals Handbook H.E. Boyer, T.L Gall)
What you should discuss is energy absorbtion. A stiff but brittle metal will not absorb as much energy before fracturing as a similarly stiff but more ductile one. The differences in specifications laid out by NHRA, SCCA, NASA, etc reflect the difference in materials properties in an attempt to place them on a relatively level playing field with respect to energy absorbtion. THAT is a fact which reflects a larger picture."
-Niles