Template Material

[monte55]

What about a pantograph. You could modify a router pantograph to hold the torch and the template could be just a drawing. A pantograph would also let you change the size of the part being cut using the same template. It would be easier than holding a torch against a template in my opinion. You could make one also. If you're not sure how to make one, you could get a drawing pantograph on e bay cheap and duplicate it in a larger scale out of metal.

[Burnt hands]

nocheepgas,

I have used thin pieces (1/4" ) of graphite plate I got on ebay.

They cost me about $18 a sq ft but for doing hundreds of pieces, I found this stuff well worth it. But for just a few pieces, alum or steel is fine.

I tried to cut it with my plasma cutter but even at 60 amps, the edges of the graphite just got red but didn't cut.

Might be overkill for your application but it made my job easy.

A big concern is cutting the graphite to make the template but I used my drill press with a milling but and a milling vise to cut the shapes.

Had fun with some friends by having them trying to cut the graphite after they cut alum and steel sheet.

[nocheepgas]

nocheepgas,

I have used thin pieces (1/4" ) of graphite plate I got on ebay.

They cost me about $18 a sq ft but for doing hundreds of pieces, I found this stuff well worth it. But for just a few pieces, alum or steel is fine.

I tried to cut it with my plasma cutter but even at 60 amps, the edges of the graphite just got red but didn't cut.

Might be overkill for your application but it made my job easy.

A big concern is cutting the graphite to make the template but I used my drill press with a milling but and a milling vise to cut the shapes.

Had fun with some friends by having them trying to cut the graphite after they cut alum and steel sheet.

Sounds like that might be worth a try, Thanks!