Gussets

[hzheng_449]

Whenever my team has to make custom gussets, we use .1" thick 6061 T6 sheet Aluminium which we cut using a bandsaw. We use Onlinemetals as a supplier, but I'm sure you can find a local supplier that also stock sheet aluminium.

Since we pretty much only have band saws and drill presses, we use a pretty low tech method of making gussets. We first CAD the gusset, then print out a 1:1 scale print. We then take the paper, center punch the hole centers, and then drill out the holes then cut the plate to the proper size.

Recently we've also used a method where we first make a template which we lasercut out of delrin (you could probably also 3D print a template), clamp the template to the metal, and then match drill out the holes.

Of course, we prefer to not have to make custom gussets. So if a COTS gusset is available, we just splurge and buy them.