I did this at TechShop Menlo Park http://www.techshop.com and Burning Man 2012.
As a contribution to my Burning Man camp (Bojon) and our beautiful art car Sil-vi, I created a big sign. This is how I went about it:
Step 1: Vector Creation
I took our logo, and converted it to a vector in CorelDraw, exported it as a a DXF file and imported it into Torchmate generating a G code to cut with our CNC Plasma cutter at Techshop.
Step 2: Set Up
I used 80 amp consumables to cut 1/4 inch steal plate and powered up all the elements of the plasma cutter shown in pictures.
Step 3: Cutting
The plasma cutter did the job for me smoothly and easily.
Step 4: Bending
Bending the sign with a step brake worked well but created lines across the metal which needed to be removed.
Step 5: Grinding
Using an angle grinder for many hours.
Step 6: Attachment
At this point I am at Burning man, working on the back of the sign to be welded onto the front of our art car.
Step 7: Welding
Final installment is a bit unusual. I would instruct you to wear a welding jacket. Do as I say not as you see me do. He, he, he..
Step 8: FUN!!!!
After hard work it's time to play. Long live Sil-Vi. We will continue to love her, make her better and enjoy her.