I was just walking through our shop at work, and looked at some rectangular tubing that I thought might be capable of being cut into saddle gusset like shapes. The biggest issue I could see here is that if I were to cut an angled section out of a piece of rectangular tubing, it would still consist of 90 degree corners. I think the saddle gussets are formed with a radius to match the tube.
I need to noodle on it a bit more. I wonder if a piece of 2 x 6 x 1/8" wall rectangular tubing would work for the starting stock for saddle gussets. It could be cut to virtually any angle. Would the square corners present a problem, as they would not "wrap" around the 2 tubes?
Steve.