Re: Gusset question again...Attn:TR
If I am double gusseting something for reinforcement, I do the top and bottom.
When we do doubles, we box in the open part between them for the added reinforcement.
If it is just a single gusset, I do it in the middle.
I've seen tubing smashed flat, and some of the gusset welds torn loose, but I have never seen a gusset slice through a bar, and I have never seen a gusseted joint fail.
I've seen the pipes fail, and some welds fail, but never a gusset.
For singles, I really think you loose some strength if you go on top.
You are sheering against the weld and trying to pull the pipe open.
Any reinforcement in the centerline of the joint is best, so on top would be too far up I would think....
Right in the middle on a single seems to have less damage to the pipe, and holds better if it's axial to the pipe.
Some people slot the pipe, and weld inside, then top an bottom outside.
I think that is overkill.
All I do is weld about an inch, then space an inch, then weld an inch....
On the bottom side I'll weld 1/2" then do what ever is reverse of the top side, except weld tight in the corner on top and bottom.
I think the alternation is the key.
I don't know the reason for this, but I see it on a lot of top dollar, professional build race cars, like NASCAR.
I've seen solid welding on top and bottom of a single gusset do just as well as an alternated weld, so I can't make a judgment call on that one.
Gussets are a low cost, high yield way to add strength and durability to any project, not just roll cages.
Anytime you need a support, don't guess, gusset!!
(OK, I know that was bad, I can smell it from here[img]/wwwthreads_images/icons/blush.gif[/img])
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