What is stronger? Guesset or brace?

[dustymojave]

So to deal with the original question of this topic...
Which is stronger? Gusset or brace?

The correct answer is that that question is like asking "which is better? Apple pie or Oranges." Because they're for 2 different purposes.

The purpose of a brace is to stiffen a portion of a structure.

The purpose of a gusset is to increase the area of a joint to de-concentrate the structural loads at the joint.

An 'X' across the roof of a roll cage does not do the same thing as gussets in the corners do. However, the ends of the diagonal members of the 'X' where they intersect the corners of the box DO serve as gussets to those joints.

[Ol'fogasaurus]

Well said Dusty!

[DeMinimis]

I think the answer lies with what the big Class 1 builders are doing. If so, then tube gussets.

[dustymojave]

For an outfit like Brenthel, each piece of tube is CNC cut and notched. Making straight short tube gussets is EZ. Making curved or plate gussets would be much more difficult and expensive. They have considerations, such as profit margin, other than what works best. Those joints are the stiff type I referred to above.

The purpose of a brace is to stiffen a portion of a structure.

The purpose of a gusset is to increase the area of a joint to de-concentrate the structural loads at the joint.

So the little triangles at the corners are VERY rigid. At the corners of the triangles the tube is suddenly vastly less stiff. FMEA would show that failure would be expected at the ends of those gussets.