A good bit of work, but not much to show for it. I’ve roughly cut out the first two pieces, and in doing so I can tell pretty clearly that I currently lack the skill to do an accurate cut with the plasma cutter. Even with wheel guides on the torch head, I can’t move my hand steadily enough to prevent skips (where the torch does not cut all the way through) or re-welds, and I doubt I’d be able to follow the line perfectly. This is a shame, as I’ve found the cutter produces a surprisingly even and precise edge with very little slag underneath, if it’s moved smoothly. This cutter can be upgraded internally for machine control (CNC); I’m really wishing I had space for an X-Y table.

Alternatively, what I could really use right now is a metal-cutting bandsaw. I have one that belongs to a friend, but it’s not made very well and despite attempts to adjust it, it’s developed a habit for throwing the blade — every few seconds. It’s probably not really up to the task, and I’m reluctant to drag it out of the attic just to realize that it’s worthless. I may end up using a jigsaw, but I really don’t like that idea either.

Anyway, here’s what I’ve got so far.