Quote:
Originally Posted by Michael 4499
Team 4499 has recently acquired a 1995 Haas VF2 and what we are doing to make gussets is first cut out stock that is big enough to fit two gussets on it as two L's. Then we chuck it up in the mill and run a holes sequence to get the hole pattern in it to then mount it to a plate tapped with those holes. After that, we bolt each side down and then it runs a sequence that cuts the perimeter of the gussets. The whole 8 gussets are done in under an hour and we are ready to assemble.
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You should investigate using tabs to make your gussets. It will save a lot of time. Essentially you contour almost the entire perimeter of the part, but you leave a tab or two connected on each side that is ~.020-.035" thick and as wide as necessary (usually .25"-.5"). If the part is thick enough you can hammer it out from the remaining stock, otherwise you bandsaw it loose. From there you can snap the tabs off with a pair of pliers - this gets it pretty close to flush. Then you sand it as flush as you can without gouging the part (120 grit 1" wide sanding belts work well). Finally you finish it off with some scotchbrite. Once you get good at this it will be virtually indistinguishable from a fully machined surface.
See an example here