We put Yosemite Sam on the mailbox this morning.
He was a favorite cartoon character of both my husband and myself. I can still hear him yelling, “I’m-a warnin’ you, Stranger!”
We found a picture of him on the net. My husband used a program that converts a picture into code the computer can recognize. We have a CNC set-up in our shop. (A computer, plus a big metal table on which we put 4′ x 8′ sheets of metal. The computer-guided torch follows the code and cuts out the design. My husband creates an attachment piece for the mailbox and welds it onto the design. I then mark salient points on the bare metal, both sides, with the use of an overhead projector.
I then paint the piece on both sides and then spray the sides with polyurethane spray for protection.
This piece is about 2 feet high and 2-1/2 feet wide.