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Re: Gussets
For out gussets, we print out the cad drawing and cut to size on a bandsaw after gluing the drawing to some 1/8" thick 6061 aluminum plate. Then we trace out whatever number we need on plate and bandsaw all of them to size. For holes, we just mark them out or use a transfer punch and drill them. When we put the gussets on the chassis, we drill through the holes on the gusseet and immediately rivet them on. This ensures proper alignment of rivet holes.
This year, we will also likely smooth out the edges using a disc sander to improve the looks.
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