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Re: R01 Question: Please save me from welding
I'm assuming your issue is that the gusset is exceeding your frame perimeter. If that's the case, the inspector will not let it slide. The gusset would be illegal as it is not included in R01.
When our team runs into this problem, we get around this with L brackets instead of gussets. Gussets attach two flush faces (the ideal method) while brackets connect two angled (usually and hopefully 90 degrees) faces.
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2014: FRC 2169 scouting/spirit, FTC 7897 Mechanical

2015: FRC 2169 Mechanical/CAD

2016: FRC 2169 Mechanical/CAD
2017: FRC 2169 Head of Mechanical
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