The material that we used for gussets was a thinner steel, which didn’t allow us to mill the slots properly. The solution was to Swiss cheese the gusset and then clean it up on the mill once we had welded it.
Here I have my fellow build lead Kyle putting the finishing touches on it.
http://sphotos-b.xx.fbcdn.net/hphotos-snc6/285146_593205977359668_2046511429_n.jpg