So I heard back from the professional metal workers about the plasma cutting. I contacted five different welding and metal manufacturing companies. Three of them told me the job was too detailed for their machines, one of them needed me to send him a CAD (Computer Aided Drafting) file to be able to give me a quote and the last one quoted the project at $250!!! Looks like I am headed back to the drawing board!
Well in the meantime, here are the preliminary plans for the mask. Enjoy!
This will be 16 gauge steel and don't worry there will be rivets!
These pieces will also be 16 gauge steel. The top piece will be secured to the back of the mouth portion of the mask. The middle rectangles will be placed over top of the eye holes and the bottom piece will be bent and bolted it into the nose hole. "So as you can see, that's coming along nicely"
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To get your mask cut from 16 gauge steel, first find a small fabrication or HVAC shop or a friend that has a small portable plasma cutting system like a Hypertherm Powermax30. Find the centerline distance from the center of the nozzle to the flat vertical edge on the outside diameter (about 11/64" for the PMX30). From a piece of 1/4" flat plywood or particle board, cut out your mask with holes. Make sure that all the dimensions are offset by the centerline distance of the nozzle. Take this wood template to your plasma cutter and have them use the hand torch to trace the template. It shouldn't take more than 15 minutes to setup and cut a simple design like this once you have the template. Also the template can be used multiple times. It should cost a lot less than $250 for 15 minutes of someone's time.
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