Are you using a single nozzle printer and building the supports with the same material that the part is printed in.
I have access to a small makerbot but I haven't really used it yet. The plastic rolls for the machine are very costly in my opinion. They do have a water soluable plastic that you can build the gussets out of if you have a dual nozzle machine. But that stuff is very pricey too.
It is great seeing someone use some of the great Technology available to us for this hobby.
I'm currently learning to use autodesk inventor. I'm trying to make a few molds to do some vacuum forming with.
Keep up the good work anxious to see the rest of the build.