Gussets

[Sohaib]

What material would you recommend for gussets - and a supplier (Preferably one that ships to Canada and/or is local). Our team doesn't have a Mill so it'd be difficult to pocket material so it'd be ideal if its something not too thick, though we do have band saws that we can cut out gussets with. Also, any specific gusset making techniques or things you've learned? Thanks!

[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.

[Sohaib]

Originally Posted by 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 then take the paper, center punch the hole centers, and then drill out the holes then cut the plate to the proper size.

So if a COTS gusset is available, we just splurge and buy them.

What sort of Bandsaw/Blade do you use and what speed do you run it at? Sorry but I'm not sure exactly what you mean by "center punch the hole centres" - if you could tell me that'd be great!

Also, other than the VEX Gussets, do you have links to any more COTS gussets? Thanks!

[EricH]

Originally Posted by Sohaib

Sorry but I'm not sure exactly what you mean by "center punch the hole centres" - if you could tell me that'd be great!

You know how to center punch a hole, right? (Explanation below, just in case you don't.) You apply the center punch at the center of the holes you want to drill. In this case, they're using the paper to mark the centers and then using the punch to transfer the mark.


Use of center punch (looks something like a metal stick with a sharp pointy end):
1) Put sharp point on exact center of hole you want drilled (use eyes to position).
2) If it's springloaded, hold perpendicular to the part you are punching and push straight down until it "snaps" (you'll feel it pop or snap or what-have-you). If it's not springloaded, hold perpendicular to the part your are punching and hit with a hammer ONCE.
3) Remove center punch from part and verify that that nice shiny ding in the part is in fact in the exact center of where you want the hole drilled. If it is, or is "close enough", go find the drill bit you want to use and a drill. If it isn't, repeat until it is.

[Sohaib]

Originally Posted by EricH

You know how to center punch a hole, right? (Explanation below, just in case you don't.) You apply the center punch at the center of the holes you want to drill. In this case, they're using the paper to mark the centers and then using the punch to transfer the mark.

Aaah, thanks!

[hzheng_449]

Yeah EricH pretty much hit the mark (pun intended). You can print out a CAD with the centers of the holes marked with crosshair, which you then center punch.

We use a craftsman bandsaw. I don't know the exact speed and what blade we run it with.

We haven't really used rivets in the past, so we use 80/20 gussets which you can get from McMaster or MSC. They're a bit pricey, but well machined and reusable.

[asid61]

For out gussets, we print out the cad drawing and cut to size on a bandsaw after gluing the drawing to some 1/8" thick 6061 aluminum plate. Then we trace out whatever number we need on plate and bandsaw all of them to size. For holes, we just mark them out or use a transfer punch and drill them. When we put the gussets on the chassis, we drill through the holes on the gusseet and immediately rivet them on. This ensures proper alignment of rivet holes.
This year, we will also likely smooth out the edges using a disc sander to improve the looks.

[lamk]

Any reason why you don't want to use the VEX gussets. Since you're in Toronto you can go to Pickering to pick it up directly from their warehouse. For our team, shipping is always the issue.

[EricH]

Originally Posted by lamk

Any reason why you don't want to use the VEX gussets. Since you're in Toronto you can go to Pickering to pick it up directly from their warehouse. For our team, shipping is always the issue.

Sometimes, COTS is not the way to go. I know, that's a radical idea. But sometimes, COTS just doesn't fit your needs, and won't be readily adaptable to them either. Which is why most teams like to have some form of machine shop handy...

[Monochron]

This may go without saying, but I would heavily recommend against Lowes brand steel gussets. Our team used some in our offseason event to attache part of our new super structure and they bend completely out of shape in our first match with them. Anything Vex thickness or above aluminum should do the trick.

[MrForbes]

Originally Posted by Sohaib

What material would you recommend for gussets

Depends on what we're building. You didn't specify what you're building, or the materials you're using, so it's kind of hard to make a good recommendation. But usually it's a good idea to use a material similar to what your gussetting.

For example, when we make stuff out of 1/16" thick aluminum tubing, we usually make gussets out of 1/16" thick sheet aluminum. Cut to size with a bandsaw or snips, and drill holes for rivets, then clamp to the part and drill a hole for the first rivet, install the rivet, drill the next hole, rivet, etc.

[z_beeblebrox]

We have a fairly unique situation (a laser cutter), but we've had success using 1/4" birch plywood for gussets.

It would be easy to make gussets like those on a band saw and drill press instead of a laser cutter.

[Seth Mallory]

We have a shear, a brake, and a finger brake in our shop. Many of our gussets are made from scarp pieces of aluminium as they are needed. It takes just a few minutes to cut, drill, and fold the gusset as needed. Then you put it on the robot and drill robot threw the holes in the gusset and attach.

[headlight]

Originally Posted by Sohaib

... Our team doesn't have a Mill so it'd be difficult to pocket material so it'd be ideal if its something not too thick ...

Am I missing something? Why would a gusset need to be pocketed?

[EricH]

Originally Posted by headlight

Am I missing something? Why would a gusset need to be pocketed?

Why would a normal frame sideplate or bellypan need to be pocketed? Think carefully...

If you can remove weight where you don't need the strength, you can save a couple of pounds that can be better used for other things.

While it is true that a gusset won't often need to be pocketed, sometimes that isn't the case--a particularly large gusset would be a prime target for pocketing in areas where the loads it's seeing don't travel.