CNC Plasma Cut Deer Head

we are using 10ga steel which is about 3.2mm.

Furthermore, Plasma Cutting is not as precise as laser cutting, so we needed a higher margin of error in our cutting.
Fortunately, in the Plasma Cutting software we can adjust the offset of the cutting tool from the theoretical cut line.
So cut a test piece and when it didn't fit, we added 2/100 of an inch, which made everything fit perfectly.

Step 2: Correctly Adjusted Plasma Cutting

With our files all sorted out, the rest of our pieces were cut out on the CNC plasma cutting table. 

A CNC Plasma table is really like a very precise arm, moving the cutting torch around to exactly where we want it, 

accurate to within 1/100 of an inch. It also looks pretty cool!

Step 3: Grinding

Plasma cutting removes metal by melting it with hot gases and blasting it away. 

Some of that blasted metal immediately resolidifies on the edges of the cut, leading to a messy, gouda-cheese looking detritus called dross. 

We remove the dross with a grinder leaving a nice, finished edge that will correctly mate with other pieces.

Step 4: Starting Assembly

All the pieces are intended to slide together with the mating slots. We need to assembly the whole thing then get ready to add some welds.

Step 5: Finish Assembly

Step 6: Welding

10ga steel should be welded around 21V and 130Amps in a MIG process. 

As we are doing small welds called tacks, we opted to increase the voltage a bit, 

leading to a hotter weld that penetrates the metal more deeply.
Every joint was tacked at least once, in an area it was least likely to be visible.

Step 7: Affixing the Base

Step 8: Crooked Antlers

We though the antlers looked a little bland with everything at a 90 degree angle, 

so we used an Oxy-Acetylene torch to heat the metal up to cherry red.

Oxy torches use pure oxygen to make a flame burn as hot as possible to heat things quickly. 

If we had used a bit more oxygen, instead of softening the metal, it would have melted it away, just like the plasma cutter. 

After heating the steel, we just added a slight twist in the antlers by hand. WEAR GLOVES!

Step 9: Mounting

Using the keyholes we created a minute ago, we attached two screws to our wall and mounted the deer head in place.