Thread: How to properly design a gusset?

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I guess any general info would be nice.
specifically for my model a build, the 2"x4" square tube frame.
I have 2 60 degree miters that will be gusseted on the inside of the tubing side walls.
I would also like to add gussets to the inside of the bend, so my questions would be

1) how is gusset leg length determined?
2) how to determine material thickness for the gusset?
3) how much material is needed for a gusset to werk properly with in its basic triangle shape? meaning I have see gussets with designs, and a radius on the unconnected side, how much material can be sacrificed for "cool"?
4) whatever I didn't think of? lol

thanks