Thread: How to properly design a gusset?

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Got out in the shop and made all of the "H" beam pieces.
I used some 3/16 x 2 1/2" scrap I had in the bin.
Laying out the cuts.

I free handed the side plates on my 14" verticle bandsaw.

After cutting out all eight pieces I hit them with a grinder to clean up.

After I got them cleaned up I stacked them together and wrapped them with tape so I could cut all of the angles at once... Much faster that way. I used a milling clamp to hold them in the H/V Bandsaw.

Once the angles were cut I did a quick mockup for welding.

Thanks for looking. I would appreciate any constructive critisizm guys.
Mark S.

Mark, Thats a good idea and good work as well. I have also always welded a support inside of my frames at the butt joint. I cut mine to fit inside of the joint and rosebud weld the piece of reinforcing plate to both frame members. Inside and outside, or two pieces per joint. Certainly nothing wrong with your "H" beam idea and it should serve you very well.

But now remember guys we are not building "Watches", there car frames. Look at any factory frame you will not find a single weld anywhere, those suckers are all riveted together.

RS

Originally Posted by Hombre259

Mark, Thats a good idea and good work as well. I have also always welded a support inside of my frames at the butt joint. I cut mine to fit inside of the joint and rosebud weld the piece of reinforcing plate to both frame members. Inside and outside, or two pieces per joint. Certainly nothing wrong with your "H" beam idea and it should serve you very well.

But now remember guys we are not building "Watches", there car frames.

Look at any factory frame you will not find a single weld anywhere, those suckers are all riveted together.

RS

Thank you Hombre, I appreciate the kudos. Good welds or not I have always done this also. For Hi-Performance use it is a simple bit of insurance that goes a long way to strengthening the joints.
And, just to add to your "riveted stock frame" observation, I guess that is why most people box the inners and weld all of the riveted joints.
Mark S.