C Gussets are a waste of time. Buy a few cases of beer with that money, at least you will get something from it.
Do not consider gearing your axle your self. Based on your previous posts, you are 100% not the person that should even consider it.
How "larger" of tires did you put on your Dana 30? If 35" or less, and your admitted few times a year light wheeling in a relatively flat area of Houston.
Note that the cast C's really don't bend unless your doing jumps and the such. The axle tubes (the pipe sections) are what bends LONG before the cast C will ever move. But even those are not likely to bend with mild wheeling a few times a year.
My feeling is that you are trying to fix a problem that does not exist.
What Jeep year?
What tire size?
Will you be jumping, high speed dune running, rock crawling?
Is $3000 in your budget for a complete Spicer Ultimate Dana 44 front axle shipped to your door from Sara Oaks at 4WD.com? That is with allow shafts, locker, gears, nodular iron cover, Dana 44 center, 16% stronger tubes than a Rubicon Dana 44 (or Dana 30, same damn thing), larger cast Cs, all built and shipped on a pallet to your house.
You'll be $350 into gears, $150 into install kit, $100 into carrier, $500 into labor to gear it. That is $1100 into the Dana 30 to just get gears changed, maybe more depending on labor in your area. And you need to do and spend the same on your rear yet... but that is no matter if you do the 30 or buy a 44. You MUST do both, no options there. After spending that $1,100 you still have a Dana 30 with weak brackets, tubes, gears and center casting. The Spicer Ultimate 44 is over double the cash outlay, but it is an overall very economical and easy way to get into a geared and factory built Dana 44 with all of the desired upgrades already done. It is a great value for a mild wheeler on 35" tires or less.