Skeleton Gussets - Internal Frame Gussets
Sorry - No Longer Available - Due to production costs.
Photos below, so you can make your own.
Many builders want to make their own frame rails, but are concerned about the strength of the joint welds and don't like the appearance of gussets bridging the gap between one section of tubing and another.
I'm one of those builders, and that's why I came up with Skeleton Gussets:
These gussets are one-quarter-inch steel, with four 3/8"-16 nuts MIG welded to the back of them.
They will be offered in 30-degree, 45-degree and 60-degree angles.
They are designed to mount inside the frame - and quite simple to use.
They will be packaged in sets of four, which is enough for two corners.
Below left is a photo of eight 60-degree Skeleton Gussets. (Enough for two sets.)
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.
A paper template is included with each kit 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.
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.
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.
Sorry, no longer available.