Hi Bass,

After the gussets are welded into place I would still groove out the fractures and weld them up, then grind perfectly flat as this way you are using both sections of metal for strength and not just loading up all the stress onto the gusset.

I know it's a bit more work but in the end it will pay off.

Cheers,
BB

I live a 24 Hour lifestyle, but every now and again I seem to fall asleep, well at least that's what my wife tells me.