Best way to make gussets?

[asid61]

I've tried to avoid using anything other than "standard" Vex gussets this year, but some parts just need the extra strength that a triangle gives you. My question is, how do other teams handle making gussets? The fastest way I have found to make them accurately enough to fit onto a machined hole pattern is to use the table saw to get outside dimensions, clamp ~10 at a time together and mill the holes, and use a bandsaw to get the final contours. The whole process takes about 3 hours to make a set, but requires an experienced member's constant attention and takes up valuable mill time.
We have tried printing out the gusset and gluing the paper to aluminum before drilling, but it often peels off, and it's hard to do multiple at once this way.