Quoted:
Well, I'm thinking about having the frame gussets water-jetted only because the gussets constrain the shape of the frame and they need to be very very accurate. Considered CNC Plasmajet, but I am concerned with the HAZ in the 6061-T6, even though I can get around it by undersizing the holes and oversizing at the edges, but that means manual finish....which would somewhat defeat the point anyways.
Anybody know of some one off waterjet places? The gussets nest on a 36x48x.125" plate of 6061-T6.
I guess I don't understand.
In my experience gussets can be anything and any shape as long as it re-enforces the structural design properly, but I haven't seen your plans.
Me thinks you might be "over engineering" certain design functions.
BTW, Today I just dropped another $1k on my project - alternator ($400), engine mounts ($450), West System Epoxy ($130), fiberglass tape ($21).
I hope you get off much much cheaper than me....