Making some "3D" numbers out of steel

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This is all out of 14g (if I recall correctly) steel. Just free handed some numbers with soapstone and cut the first one out on the bladerunner. Tried to cut the second one out and the blade went dull and used the plasma cutter. Cut out 4 pieces of them, clamped them out together and put them in the vice and used a flap wheel to try and get all of them as even as possible. Must say it's much harder than I expected. Cut out some straight pieces and started to weld. The first number I did all tig, then ran out of gas and didn't want to refill because I was in the middle of moving and didn't want to lug around the heavy tank, so I used the mig with some flux. Anywho, just finished the second number today and hit it with the flap disc for a LONG time to get it smooth. Still needs some more work for sure, but not too bad for my first time doing something like this. I probably have a good 8+ hours into these 2 alone.Once I'm done I'm going to make some type of background, paint them and mount it on the wall. Some of the inside corners I can't get the flap disc in there, anyone have any tips for smoothing out those welds?Last edited by Gamble; 09-10-2012 at 10:24 PM.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:File or Die Grinder for the hard to reach spots.