Metal Reindeer Sculpture

Materials:

3/16" rod steel
1/4" rod steel
3/8" rod steel
16-gauge sheet steel
3/4" tube steel
1/2" square stock steel
two 1" ball bearings
tape measure
steel chop saw
grinder
bending fixtures, various sizes
welding equipment
plasma cutter
welding safety equipment including welding mask, fire-retardant gloves
safety glasses
spray bottle
white distilled vinegar
spray clear coat

Steps:

1. Cut all rod steel to the following specified lengths using a steel chop saw and wearing safety glasses:
Back legs:
- two 3/8" x 39" pieces
- two 1/4" X 35" pieces
Front legs:
- two 3/8" x 36" pieces
- one 1/4" x 32" piece
Belly:
- one 3/8" x 32" piece
Back:
- one 3/8" x 28" piece
Head:
- two 1/4" x 18" pieces
- two1/4" x 9-1/2" pieces
Neck:
- three 1/4" x 3-1/2" pieces
- two 1/4" x 12" pieces
Ears:
- two 1/4" x 6" pieces
Tail:
- one 1/4" x 10" piece
Antlers:
- two 1/2" x 1-1/2" pieces
- two 3/4" x 1" tube pieces
- two 3/8" x 16" pieces
- two 3/8" x 8" pieces
- two 3/8" x 6" pieces
- two 3/8" x 2" pieces
Body supports:
- one 3/8" x 4" piece
- one 3/8" x 7" piece

3. Tack-weld back legs, front legs, neck, head and antlers.

4. Assemble back legs, front legs, neck and connect together with back, belly rods and body supports (figure B). The body is now complete.

5. Fill out the body with zigzag "tack and bend" to fill out body. Start with the legs working up toward the back. Fill out the sides of the body and the front chest area (figure C).

6. Fill out the head with the zigzag "tack and weld" and attach the 3/4-inch tube inserts on the top of the head. The antlers will be welded to these later.

7. Plasma cut the 16-gauge sheet steel pieces into workable skin sizes for the deer. Cut small narrower strips for the legs and larger pieces for the body sides and chest. Plasma cut four pieces to be used as "eyelids." Grind or polish the plasma cut pieces to remove the sharp "slag" and to give a little texture.

8. Prep weld the eyes by attaching two of the eyelids and one 1-inch ball bearing. Attach the finished eyes to the head zigzag and fill out the rest of the head with the 16-gauge plasma cut pieces (figure D).

9. Attach the 16-gauge "skin" to the legs and body. Attach the head to the body and attach the tail and ear pieces. Drop in the pre-weld antlers. The 1/2-inch square stock attached to the bottom of the antler fits into the 3/4-inch square tube (figure E).

10. To add a rustic patina, in a spray bottle mix 1:1 ratio of white distilled vinegar and water, about one cup of each. Mist over the entire sculpture. Allow to dry overnight. Spray again as needed (figure F). Apply a clear coat to seal the finish and to provide a sheen to your metal reindeer sculpture.