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Unread 27-05-2014, 12:38
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Re: What is the easiest way to cut make aluminum gusset

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.
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