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Old 11-28-2018, 11:09 AM   #1 (permalink)
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Bent tube gusset fixture

I was reading through mcutler1 thread and there was some discussion about this kind of gusset and it reminded me that I started designing a fixture to make these years ago.





I have not sense had a need for the gussets so the project was abandoned but Im thinking it could be fun to finish and I can share the files to make it if anyone is interested.

So lets hear some input on what I have so far.

The idea was to bend a piece of 1.5" tube to a 90 in as short of piece of tube as possible. There would then be a simple fixture the bent tube went in and acted as a saw guide to cut to the 70 degree section needed. (I hadnt gotten around to drawing this up yet)





Then the main fixture:






Biggest issue will be hole saw depth. You will have to trim 2 or 3 times for the hole saw to make it all the way through the cut. Not a huge deal but annoying.

My second concern is clamping. Right now its a pivot kinda clamp that is tightened with a nut on the back of the 1/2" bolt that is in the center. With this in a drill press Im worried if this type of clamping will suffice. Input here is appreciated.

Everything was designed around being plasma cut from 1/4" plate so i could build this on my home plasma. Thicker plate could cut down on number of parts.

Lets here some input on how to maybe simplify thew thing while keeping it easy to build for the home shop guy.

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Last edited by NorIdaWheeler; 11-28-2018 at 02:06 PM.
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Old 11-29-2018, 04:32 AM   #2 (permalink)
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Maybe I'm just being paranoid but it seems like having a tube gusset that's already bent would have very little strength in compression (compared to a normal notched tube gusset) unless you back it up by installing a plate in the dead space behind it.

I'm sure it's great for A/B pilliars where you want a little extra room when getting in/out.
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Old 11-29-2018, 04:44 AM   #3 (permalink)
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Cool idea, good to see people being creative with tool design. Yes, the long cut is a pain been there endured that.
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Old 11-29-2018, 04:55 AM   #4 (permalink)
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What's the radius of the bend? Could you bend a full circle or a spiral and section it out to then notch?
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Old 11-29-2018, 05:31 AM   #5 (permalink)
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To eliminate the hole saw issue, could you use an annular cutter?
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Old 11-29-2018, 05:53 AM   #6 (permalink)
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Nice jig, I've always liked these style gussets
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Old 11-29-2018, 07:03 AM   #7 (permalink)
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Quote:
Originally Posted by arse_sidewards View Post
Maybe I'm just being paranoid but it seems like having a tube gusset that's already bent would have very little strength in compression (compared to a normal notched tube gusset) unless you back it up by installing a plate in the dead space behind it.

I'm sure it's great for A/B pilliars where you want a little extra room when getting in/out.
I've brought this up numerous times and the gist of what I'm told is for a trail rig it doesn't matter but for go-fast you want to use a straight tube that's notched.

I've never built one of these gussets for that reason alone, but I may be willing to do them on my next rig with a dimpled plate behind the gusset. I hadn't thought of that before...
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Old 11-29-2018, 07:09 AM   #8 (permalink)
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Just make a tubing wrap and cut with plasma and clean with grinder. That's how I do them. I freehand the notch drawing on the tube, plasma and clean up. Once I get one good I wrap with tape, cut it along notch, then peel it off and reapply to other tubes to use as a template.

Also you can weld a hole saw to each end of a piece of tube to make it whatever length you need just cut the threaded end off one of the saws and the blades off the other saw.

Last edited by 65Chevy4x4; 11-29-2018 at 07:11 AM.
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Old 11-29-2018, 07:10 AM   #9 (permalink)
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Quote:
Originally Posted by arse_sidewards View Post
Maybe I'm just being paranoid but it seems like having a tube gusset that's already bent would have very little strength in compression (compared to a normal notched tube gusset) unless you back it up by installing a plate in the dead space behind it.

I'm sure it's great for A/B pilliars where you want a little extra room when getting in/out.
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Originally Posted by whitneyj View Post
I've brought this up numerous times and the gist of what I'm told is for a trail rig it doesn't matter but for go-fast you want to use a straight tube that's notched.

I've never built one of these gussets for that reason alone, but I may be willing to do them on my next rig with a dimpled plate behind the gusset. I hadn't thought of that before...
Im not here to debate the strength of the gusset. It has been brought up around here many times before by guys far smarter than I. I have just seen a lot of discussion about the best ways to build this style so I ran with it.


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What's the radius of the bend? Could you bend a full circle or a spiral and section it out to then notch?
I designed it based on my 1.5"dia, 4.5" CLR jd2 die. I bet I could get a 210 degree bend out of it and be able to get three gussets out of one bend. That would be killer!
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Old 11-29-2018, 07:12 AM   #10 (permalink)
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To eliminate the hole saw issue, could you use an annular cutter?
Definitely! However I doubt I would have the rigidity to do it in my drill press. If I incorporated a bearing block like a standard tube notcher that might be rigid enough to get it done.
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Old 11-29-2018, 07:55 AM   #11 (permalink)
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Here's a pic of the style of long hole saw that i have made. This one made by a friend. I just tacked it all together in a piece of large angle iron and turned out straight and works good.

Last edited by 65Chevy4x4; 11-29-2018 at 07:58 AM.
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Old 11-29-2018, 08:34 AM   #12 (permalink)
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neat ideas all around......... looking forward to where this goes
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Old 11-29-2018, 08:58 AM   #13 (permalink)
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Here's a pic of the style of long hole saw that i have made. This one made by a friend. I just tacked it all together in a piece of large angle iron and turned out straight and works good.
fuck. yea.
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Old 11-29-2018, 10:39 AM   #14 (permalink)
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I would run a clamp with 2 bolts and 2 legs that fit to the tube.

If you finish designing it and want to shoot me the dxf files I can cut it out of 1/4" plate and give it a go. I have a mill and long hole saw. If this works it would make life easy.
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Old 11-29-2018, 11:46 AM   #15 (permalink)
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Once I get one good I wrap with tape, cut it along notch, then peel it off and reapply to other tubes to use as a template.
.
I have used Aluminum as the pattern, being much easier to trim and fit. Then it can be transferred to steel. I keep the pattern in case I need to make more in the future.
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Old 11-30-2018, 09:22 PM   #16 (permalink)
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i do this, saw it on here years ago.
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