I've searched high and low with no real answers, both on and off HT, trying to figure out where to buy such items.
My question is: where does one purchase gussets like the ones pictured below? or are they made? If so, please tell me how.
Im trying to have my main hoop roll bar gusseted to my B pillar.
thank you

 

they are made with dimple die's

you can buy them here: http://tricktools.com/

 

so, sheets of 1/8" metal welded in then holes punched out?

 

Make a template out of paper. Trace the template onto .050, .065(16ga) or your choice of thickness cold rolled mild steel or whatever your racing organization/sanctioning body allows/dictates. Cut it, trim if necessary. Decide on the size of dimple die. Mark your gusset. Take appropriate hole saw and drill the holes. Shape/slightly bend the gusset so it adheres to cage/body nicely. Dimple the holes in your shop press, and weld it in place. I think .050" or thinner is a more common size sheet metal to use for gussets. However, I made mine out of .065" (A-pillar bar to body, door bars that form an X).

 

Usually it's like .065 material. The dimple die stiffens the material.

 

hmmm ok I think I understand, but I'm not the welder. If I show your response to a competent welder/fabricator, will he fully understand?
Thank you!

Sims,
How does the dimple die increase the strength?

 

Yeah, competent welder/fabricator should have no problems making those gussets if you show him pics of what you want and tell him the wall thickness of the material you want to have them made out of. Not everybody has dimple dies at their disposale though, as they're somewhat expensive (check tricktools.com or ebay has them as well at a better price).

When you dimple the holes on the sheet metal, it strenghtens it by improving its torsional stiffness I believe. It's harder to twist the sheet once you've "dimple died" it.

As far as sheetmetal thickness, FIA allows .039" or thicker I was told. I'm too lazy too check if SCCA, NASA mentions anything about gusset sheetmetal thickness, and I know NHRA doesn't say anything about it. Personally, .065" would be the minimum I'd go with (any thicker is probably too overkill/additional useless weight), but I'm no engineer, just a "garage fabricator".

 

A picture of a dimple die set :

 

Any cage builder should have a set of these in his shop. atleast all the fabricators ive been to have them!

 

Or you could use one of these with the punch/flare die kit which works on up to 16 gauge steel and is much faster.

 

old thread I know but heres my contribution to future searchers...worked great for me.

https://honda-tech.com/forums/welding-fabrication-53/diy-dimple-die-tool-lol-2553430/

 

anything .040 and thicker is fine... as is thinner as once the sheet metal is dimpled and welded its pretty stong... .065 and thicker is unnecesary, heavier and IMO more work the thicker it is.