[mrnoble]

Let's say you only need a few custom gussets, and you don't have access to a CNC, water jet, or other machine shop. Here's what my team has done.

-CAD the part.
-print a 1:1 drawing (full scale, in other words) onto paper.
-using spray adhesive, attach the drawing to a piece of sheet metal.
-cut out the part carefully on a bandsaw.
-sand and file the edges.
-using an automatic center punch, line up the holes.
-drill out the holes using a drill press.
-remove the paper and clean the part.