The gussets felt like real hand made parts. I started with the trimming per drawing, but this soon turned into an iterative process of trim, check fit, trim, check fit over and over until I got the fit okay.
There seems to be potential here to ruin edge margins on the gusset and on the weld mount and firewall stiffener. I made lines on the gussets where holes would eventually be so I could see them thru the holes. I also measured and made lines on the weld mount to help ensure I got this gusset in the right location.
We weren't suppost to drill the weld mount holes to the auxillary longerons yet. Well now they tell me. But I'm glad I did because I'll use those holes to backdrill the top (bottom) of the gussets by pulling back the side skin.
The gusset has two bends so I used this Harbor Freight tool to bend it slightly. One side bends up the other bends down. The tool bends more than the aluminum does.
