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Re: Best way to make gussets?
If a drill press is your only tool, you can use 0.1" perf board as a template, at least for right angles (you can also use it for 37/53 degree angles, you know a 3-4-5 right triangle). Mark the holes you're going to drill, clamp, and match drill 1/16" pilot holes using the perf board, remove the template, then follow up with your rivet/bolt size. I've also used this trick for laying out control panels and LED arrays - nice even spacing with little fuss.
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