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Tube Gussets



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Old 12-24-2008, 10:56 AM   #1
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Tube Gussets (lots of pics)

Of course you can buy brackets and gussets, but we all know how it is to mail order something. You think you have plenty of time for shipping, then you find out on Friday that your package hasn't been shipped. So you make no progress on that weekend.

Here is how the professionals do it and here is a pic of some aftermarket gussets you can buy.



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Last edited by dott; 12-24-2008 at 11:02 AM..
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Old 12-24-2008, 10:57 AM   #2
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Here's how I made my tube gussets.
My roll bar is made of 1-3/4" tubing, so I used the same size material for the gussets.
Start by cutting a 30 degree angle on the end of a tube.

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Old 12-24-2008, 10:57 AM   #3
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Rotate the tube and cut another 30 degree angle, leaving about 3/8" between the close ends of the cut. Here's what you end up with.



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Old 12-24-2008, 10:58 AM   #4
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Now you have to cut the short end out. Here are two methods and the result.





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Old 12-24-2008, 10:58 AM   #5
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Here's the tricky part. You need to cut the top back, but it's hard to hold the tube. Maybe this step should come before the previous step.



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Old 12-24-2008, 10:59 AM   #6
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This is the profile of what you are trying to make.

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Old 12-24-2008, 10:59 AM   #7
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Now the legs have to be straightened out.





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Old 12-24-2008, 11:00 AM   #8
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Here's what they look like after deburring a little bit.



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Old 12-24-2008, 11:00 AM   #9
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Here's how it fits now. It will take a little tweaking to make it fit the joint. Of course, the fit depends on your welding ability.



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Old 12-24-2008, 11:01 AM   #10
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BURN, PAINT.............WHEEL.





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Old 12-24-2008, 11:50 AM   #11
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nice I like that Idea
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Old 12-24-2008, 12:10 PM   #12
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Wonderful write up there dott. Looks good.


I'd like to add to it, by saying to pay close attention to your cut-off pile as well. Many times you can find a small drop that'll work as a starting point for a gusset or a tab somewhere else on your cage.
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Old 12-24-2008, 12:49 PM   #13
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Very nice work.
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Old 12-24-2008, 01:13 PM   #14
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That a stockcar trick looks good..
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Old 12-24-2008, 03:58 PM   #15
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i make those from scrap ... good write up dude... i've always liked the look of em a lot better than a flat triangle welded in
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Old 12-24-2008, 10:46 PM   #16
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sweet nice job another trick you could do if you need or want a bigger one is to use poster bourde and make the pattern and trans fer it to some 18 or 20 guage sheet metal ....use a piece of scrap tube to form it and wahla a bigger corner brace.....

yours is a hell of alot cheaper than buying them things,,,,,,,


always keep your drop off pieces ......
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Old 01-06-2009, 10:34 AM   #17
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Looks great Dale. I didn't know where your cage was cracking and now I see. Nice addition. Hopefully that holds better.

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Old 01-06-2009, 02:04 PM   #18
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that is beautiful....very nice writeup.
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Old 01-06-2009, 02:31 PM   #19
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Nice write up. Thanks for the info.
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Old 01-06-2009, 04:24 PM   #20
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Not to downing your write up dot. But id reather have a peice of tubing like you your first pic. Lots stronger,easier to make and spends the load or force out over the cage more. Which is stronger over all in a cage in a roll over.

I never seen a pro cage built with these. I have a framily freind that builds pro mod,top fuel and pro stock cage has never heard of them. It has to be some kind of dirt car junk trick. .He said he didnt see the point in them. its better to spend the load out over the cage. More triangals the stronger the cage.
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Old 01-06-2009, 04:45 PM   #21
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id reather have a peice of tubing like you your first pic...................It has to be some kind of dirt car junk trick. .He said he didnt see the point in them.
That's fine if you have a tube bender.

The first one is in a WRX.

As I said in the first post "you find out on Friday that your package hasn't been shipped".
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Old 01-06-2009, 04:47 PM   #22
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But id reather have a peice of tubing like you your first pic. Lots stronger,easier to make and spends the load or force out over the cage more.
these are not to replace normal triangulation... but to add strength where someone might use a small flat piece of metal as a gusset instead
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Old 01-06-2009, 04:58 PM   #23
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Why do you need a tub bender to make a straight peice of tub with fish mouths on each end of it. Or did you mean a tub notcher. You can do fish mouths with a chop saw just like a notcher.
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Old 01-06-2009, 05:48 PM   #24
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those things are designed to give more weld surface over the joint.
and for what dale used them for they will definetly stiffen that joint up alot with out putting more tube all over it
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Old 01-10-2009, 09:47 AM   #25
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Quote:
Originally Posted by RamRock
I never seen a pro cage built with these.
Here ya go.
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Few random progress pics....
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