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Re: Gussets
Yeah EricH pretty much hit the mark (pun intended). You can print out a CAD with the centers of the holes marked with crosshair, which you then center punch.
We use a craftsman bandsaw. I don't know the exact speed and what blade we run it with.
We haven't really used rivets in the past, so we use 80/20 gussets which you can get from McMaster or MSC. They're a bit pricey, but well machined and reusable.
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