Cage Corner Gussets

I decided that I didn't really want to do any real work today...so I made a new radius punch for forming cage corner gussets. The pictures below are for a 90 degree joint in 1.75" tubes. I also have a punch for 1.5" For door "X" braces I generally just form a long channel and then let the builder cut it to size. Just wrap your thin paper template around it, mark it, and go nuts with your cutting tool of choice. If you can explain/draw what corner joint you are fitting I can also make you a pre-fitted gusset to match.

http://i140.photobucket.com/albums/r6/yetiult/CornerGusset1-1.jpg


http://i140.photobucket.com/albums/r6/yetiult/CornerGusset1.jpg



Edited 1 time(s). Last edit at 03/08/2007 03:48PM by Tim Taylor.

I need about 24 of these.

Sending you a PM.

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Grant Hughes

I don't "need" any, but they are so sexy I want some!
What gauge are they? I really don't understand the requirement (CARS) for the gussets to be the same thinkness as the cage tubes...

-Martin.

This is what the current gussets are:



I can't really go much thicker...possibly out to 14Ga before I overload my urethane die. I'm unfamiliar with any requirement that they me the same thickness as the cage tubes.

The stock 90deg gussets should be available at a retail level from these guys (www.polyperformance.com) and possibly others in the next few weeks.

Edit:

I wanted to try out the new pattern for these gussets and here is the result. This is with absolutely no grinding...you just hold them in the corner and weld. Please excuse the wobbly welds I'm a little out of practice on tubes these days.











Edited 2 time(s). Last edit at 03/09/2007 10:54PM by Tim Taylor.

Wobbly welds ???? What are you talking about those welds are damn sexy. I wish I could weld like that.

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Cheers
M.Samli
Phoenix AZ
Gaylant VR4
EVO III GSR (Stolen)


Rallies are no place for traitors

Will these have the 'bite' out of the corner where the tubes meet? This is specified in the FIA rules and is there to allow visual inspection of the weld under the gusset.

Regards,
Mark B.

FIA Appendix J Article 253 Safety Equipment (Groups N, A, B, SP)

8.2.14 Gusset :
Reinforcement for a bend or junction made from bent sheet metal
with a U shape (drawing 253-34) the thickness of which must not
be less than 1.0 mm.
The ends of this reinforcement must be situated at a distance from
the top of the angle of between 2 to 4 times the diameter of the
biggest of the tubes joined.

Drawing #253-34

Tim, your gussets look great, in order to be FIA compliant all you have to do is to notch the 90 degreee angled corner a smidge, not a big deal.

Take look at this if you haven't already http://www.fia.com/resources/documents/994546964__AppJ_Art_253.pdf

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Cheers
M.Samli
Phoenix AZ
Gaylant VR4
EVO III GSR (Stolen)


Rallies are no place for traitors

Corners cut out are not required in FIA rules nor do any of the FIA homologated cage kits come with gussets with corners cut out.

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Grant Hughes

Then could you do it as a favor to tech inspectors who have to somehow be able to verify a complete weld on the tubes being gusseted? This is particularly important when issuing a new logbook; this is the time when every mm of welding should be checked. (And I swear this was in an FIA gusset drawing at one time.....I need to re-check.)

Regards,
Mark B.

The notch is shown in 253-16A, but doesn't the hole in the middle of the plate give enough access to see the weld?

Fear not, the off-road guys have asked for a corner notch to allow water and other debris out of the corner so they will be available both ways.

Tim

Good deal Tim. Thanks!

BTW, how about angles other than 90 degrees?

Regards,
Mark B.

We're talking about 80, 100, and 30 degrees. Should handle main hoop X, most door Xs, and doorbar to a-pillar reinforcement.

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Grant Hughes

This is what is currently in the works. Questions, suggestions, illuminating insight, biting sarcasm, and general kibitzing are invited.

Tim

damn, that's nice.
I may build Sooper Bitchinâ„¢ motors and Sooper Bitchinâ„¢ Suspenders, and I have made stuff like that what? 19 years ago, but it shoooore weren't pretty like this stuff.

Ted you should sell these things like Hotcakes, and make a million dollars!

Then you can get that 16v manifold for VW I put in the want ads.

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

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