What is the easiest way to cut make aluminum gusset

[Chris is me]

Some CNC routers can handle thin aluminum just fine. We made our lexan gussets and tubing on one for this year's game.

Gussets don't really have to be precise parts though. You could probably make do with a vertical band saw to cut the pattern of the gusset out and a drill for the holes. If you're doing a standard hole pattern you'll need a bit more effort than that, but it's just a matter of locating the holes accurately.

As sanddrag said a sheet metal shear will also do the trick quickly.

[Jon Stratis]

The quickest way, by far, is a sheer. Give me a piece of aluminum and some desired dimensions, and I can have a gusset plate made in under a minute on our sheer.

That said, probably a cheaper route would be a bandsaw. You also have added versatility with a bandsaw, as you can cut your extrusion on it as well.

Perhaps the cheats route possibly would be with a pair of snips. Get a good pair, and just cut the aluminum by hand with them.

[roystur44]

Try making your gussets out of .125-.187 thk Lexan. Lexan is just as strong. You can be real creative with a router and using jigs to cut the outside shape and then transfer punch the holes. The Lexan can even be bent with a simple pan brake.

[hrench]

Originally Posted by roystur44

Try making your gussets out of .125-.187 thk Lexan. Lexan is just as strong. You can be real creative with a router and using jigs to cut the outside shape and then transfer punch the holes. The Lexan can even be bent with a simple pan brake.

Lexan, a brand name for polycarbonate, has average tensile strength of 50-80 mpa. Aluminum alloys run the gamet of 5052-h32 at 193mpa to 6061 T6 at 300 mpa.

Lexan is a great material and its nearly unbreakable because it flexes, but it is not 'just as strong'. There are no airplanes made of polycarbonate.

[Chris is me]

Originally Posted by hrench

Lexan, a brand name for polycarbonate, has average tensile strength of 50-80 mpa. Aluminum alloys run the gamet of 5052-h32 at 193mpa to 6061 T6 at 300 mpa.

Lexan is a great material and its nearly unbreakable because it flexes, but it is not 'just as strong'. There are no airplanes made of polycarbonate.

I think his point was saying a Lexan gusset of those thicknesses (>.125 in) is "just as strong" as a .09 metal gusset. Adequate for the job being done, probably won't fail in places that your rivets wouldn't fail first.

[asid61]

We bandsaw ours. Just make sure the holes are drilled accurately (spacing wise). If you have a manual mini mill then I would use that for drilling the holes, as our robot had to have holes drilled on it, which is a pain.

[JohnFogarty]

Shearing is the better way to go, but we band saw cut all of our gussets this season as well.