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Unread 27-05-2014, 15:15
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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.