Skeleton Gussets - Internal Frame Gussets
Sorry - These Are No Longer Available - Due to Production Costs.
(Simple to Manufacture - But Very Time-Consuming)
Photos below, so you can make your own.
We made these for our Mid-Engine Chevy S-10 Project - to give the frame some added strength and rigidity.
Below on the left is a photo of eight 60-degree Skeleton Gussets. (Enough for two sets.) They are made from 1/4" steel plate. We used 3/8" 'heavy nuts' to make sure they would stay in place. It also made them very easy to weld on. Another good choice for nuts is the large 'square nuts.
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On the right is a tube being readied for the installation. It is important that any internal welds be removed to allow for the gusset to sit flat against the inside of the tubing.
Make a paper template to accurately mark the outside of the tubing for the mounting holes. Once the holes are drilled, the gussets are mounted in one of the tubes.
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The holes may be drilled a touch over 3/8" - or larger. If you plan to 'Plug-Weld' the bolt holes, for added strength, then I'd suggest a 5/8" to 3/4" hole instead. That way, the bolts may be removed (one at a time) after welding the joint - then the tubing may be welded to the gusset from the outside of the tubing - greatly adding to the strength of the joint.
The below left photo shows the tubing set up and ready for welding.
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Once the joints have been welded, such as the tubing joints on the right, the bolts can be removed (one at a time) and the gussets can be welded, through the bolt holes - to the tubing, for additional strength. Then the welds can be ground and detailed.
