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young_gun
Ha yes, sorry i would have commented but was away.
Looks cool what you've done with the end. Didn't expect it to happen so quickly. Hope it works. what are you planing to do with the brake cable bosses?
the plans for the gussets are noice. Yeah i wouldn't go for the chainstay gussets either for much the same reason.
regarding the attachment of the ends i would go for a threaded end. Countersinking, as @trunkie said, sounds risky due tot he loss of material and the joint to the end with the stays is probably somewhere where you wouldn't really want that considering the stress (I think) it would be under.
@santino I thought the cost for changing dropouts/ends was much higher, obviously dependant on the builder, but around the £80 mark.
And @young_gun , you can never go too far.
For example: