I've read and seen some different views concerning gusseting. What I'd like to know is, when you gusset a joint, does the gusset go inside the joint, like halfway down the diameter of the tubes, or on top of it. I know which would be easiest, but would like to know which is best.

I am pretty sure that you gain more strength by going in the middle of the joint.

But I would be worried about it having a prying effect on the tube like that:confused:. I suppose thats what I'll do though.

Put the gussets as close to the centerline of the tubes as possible. You want to try to put them in the same plane as the work point (sorry for the math talk, I'm an engineer). Try to keep it as symmetric as possible.

It's only my opinion, but I hope it helps.

Edit: As far as prying on the wall of the tube, the circular section of tubes helps to spread the prying out over a larger area, so it's not as bad as it is on plates. But you are right, it is still a concern.

It will also look a lot cleaner if the gusset is centered

rule of thumb (as taught to me by old timers) is on a bend go 1 1/2 times the tube diameter from the center of the bend.
ie: if you have a 2" rollbar and want to gusset the top bend you would go 3" in each direction and dont weld the middle where the actual bend is at.

If doing a floor plate same applies but weld all solid.

weld all gussets on surface of tube. allow time for tube to cool

between passes or you may warp the tube.

be sure to use flat plate at least as thick as the tube.
i have seen some people use pieces of the tube and cut it to fit in the corners (where the cross bar welds to hoop) and weld it there. hope it helps

The main benefit of gussets is you are increasing the inches of weld holding the tubes together. I agree that a symetrical load just feels better but I think an external gusset will get the job done. If you run in sand a lot, large external gussets would help the cage stay on top of the sand.

One of the nicest gussets I've seen was thin sheet on the outside, the trick part was they bent the exposed edge 90 degrees and fit it to the tubes.