What is the easiest way to cut make aluminum gusset
 

Our robot this year was mainly make of plywood, masonite and hockeystick. We did some welding and bend some steel to support our main aluminum column. Everything was bolted together.
It was a simple and effective robot and it got us to St. Louise.
In order to prepare for next year we would like to start building superstructure using extruded aluminum tube and rivets. We can certainly buy pre made gusset by vexpro but because we are in Canada, shipping cost and time is an issue. Vexpro Canada is out of stock a lot of the time. I have access to a CNC machine shop but I only want to bother them with the big ticket item. What is the easiest way to make/ cut your own .09" thickness aluminum gusset for a school with minimal resource. I can invest in some new tools if they are less than 1K. The school have a lot of equipment but they are all wood working machine thus the plywood masonite robot.

Re: What is the easiest way to cut make aluminum gusset
 

We made our .125" thick 6061 gussets on a sheet metal shear. Really easy. And you could do a jig to drill on a drill press if you wanted to rivet or bolt them rather than weld. If you want to save weight, you can go through it with a big bi-metal hole saw.

Re: What is the easiest way to cut make aluminum gusset
 

In order to cut small and complex shapes (like gussets and brackets) you'll need a vertical band saw. These are cheaper and can be purchased in table-top sizes. A tool like this in invaluable for cutting aluminum, wood, polycarbonate, and other common materials found on a robot. Out of all the tools that a team could have, a vertical band saw would be #1 on my list.

If you're going to be cutting tubing and extrusion then you'll need a horizontal band saw. Someone correct me if I'm wrong, but a chop saw should work as well provided you use the correct blade.

Re: What is the easiest way to cut make aluminum gusset
 

Some CNC routers can handle thin aluminum just fine. We made our lexan gussets and tubing on one for this year's game.

Gussets don't really have to be precise parts though. You could probably make do with a vertical band saw to cut the pattern of the gusset out and a drill for the holes. If you're doing a standard hole pattern you'll need a bit more effort than that, but it's just a matter of locating the holes accurately.

As sanddrag said a sheet metal shear will also do the trick quickly.

Re: What is the easiest way to cut make aluminum gusset
 

The quickest way, by far, is a sheer. Give me a piece of aluminum and some desired dimensions, and I can have a gusset plate made in under a minute on our sheer.

That said, probably a cheaper route would be a bandsaw. You also have added versatility with a bandsaw, as you can cut your extrusion on it as well.

Perhaps the cheats route possibly would be with a pair of snips. Get a good pair, and just cut the aluminum by hand with them.

Re: What is the easiest way to cut make aluminum gusset
 

Try making your gussets out of .125-.187 thk Lexan. Lexan is just as strong. You can be real creative with a router and using jigs to cut the outside shape and then transfer punch the holes. The Lexan can even be bent with a simple pan brake.

Re: What is the easiest way to cut make aluminum gusset
 

If you want to go the cheap route, this Electric Sheet Metal Sheer from Harbor freight could do the job. Though it is only rated for 18 gauge metal (0.04" thicknes), you may be able to find a pricier one that could do thicker.

Using a large sheer like the others suggested is going to give you much better cuts, control, and variety of material, but at the cost of money.

Re: What is the easiest way to cut make aluminum gusset
 

Lexan, a brand name for polycarbonate, has average tensile strength of 50-80 mpa. Aluminum alloys run the gamet of 5052-h32 at 193mpa to 6061 T6 at 300 mpa.

Lexan is a great material and its nearly unbreakable because it flexes, but it is not 'just as strong'. There are no airplanes made of polycarbonate.

Re: What is the easiest way to cut make aluminum gusset
 

I think his point was saying a Lexan gusset of those thicknesses (>.125 in) is "just as strong" as a .09 metal gusset. Adequate for the job being done, probably won't fail in places that your rivets wouldn't fail first.

Re: What is the easiest way to cut make aluminum gusset
 

We bandsaw ours. Just make sure the holes are drilled accurately (spacing wise). If you have a manual mini mill then I would use that for drilling the holes, as our robot had to have holes drilled on it, which is a pain.

Re: What is the easiest way to cut make aluminum gusset
 

Shearing is the better way to go, but we band saw cut all of our gussets this season as well.

Re: What is the easiest way to cut make aluminum gusset
 

Sorry I have no experience with metal work. When I google "sheet metal shear" there seems to be many different type of sheet metal shear. Can you point me to the one you're using. A picture or a link will be fantastic.
Thank you

Re: What is the easiest way to cut make aluminum gusset
 

A gusset or bracket CAN be cut with a hacksaw or coping saw. It takes a few minutes extra to do it completely by hand. Buy good quality blades, and finish the edges with a sander (or by hand with a file and sandpaper).

Holes are made with an electric drill.

One step up is a Band Saw or a Jig Saw. A few hundred dollars for a good one. be sure it can run SLOW enough to cut metal (Most run fast for wood, you can change a pulley to slow it down). A little more dangerous, but certainly OK for a typical high school student.

Another step up is a metal shear capable of cutting 0.090 or .125 aluminum. As you found, there are thousands of choices, some costing as much as a car.

Beyond that are milling machines, CNC Routers, and more, all in the multi-thousand-dollar range. I agree, asking your CNC shop to cut gusset plates is like asking your doctor to wash your clothes: You surely can do a fine job yourself.

Re: What is the easiest way to cut make aluminum gusset
 

Sorry I wasn't clear. This is what we use:
http://www.westauction.com/archive_i...34_1098203.JPG

Re: What is the easiest way to cut make aluminum gusset
 

Ah we have one similar at the school but I'm not sure if it will cut 0.09". The teacher said the one we have is designed for 0.03". I have use it to cut 0.03" many time for this year's robot. I'll get the model number and look it up. Thanks for the quick reply.