The circular gussets were cut from thin plywood.
Some times the gussets are simply rectangular in shape, but in this case they are circular (same strength, but less weight).
Leo is cutting a circle from the plywood.
Leo found that the suggested method of stacking and clamping multiple layers of thin plywood did not work well. The method he found the most success with was clamping one sheet of plywood and drilling a single gusset at a time. Two sized hole saws are used: 3 1/5 inch for the large gussets, and 2 1/8 inch for the small gussets.
Leo is cutting the features in the gusset.
Each gusset must be trimmed to the application. Many are simply cut in half, but some must have notches for spars, etc. The jig saw saves a lot of time.
Leo is showing John how to sand the rough edges that the jig saw left,
or is John supervising Leo?
Finished gussets, nice job Leo!
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