Cutting complex outlines

[Echidna]

Hi guys and girls!
I would like to have some suggestions about the way to cut complex outlines in 3mm and 5mm steel. I find it very difficult and dangerous to make them using my jigasaw and angle grinder...
I did the part (it's a brake pedal) shown in the pic but it was a lot of work. So, is my only hopw to buy a plasma cutter?
Could you show some examples of your cuttings with your plasma cutters? Is the quality of the cuts good? Thanks in advance!

 

[Echidna]

Here is the part i was talking about.
Very difficult, dangerous and time consuming to make with a jigsaw!

 

[Sparkey]

Hi Echidna! for what type of car is your pedal?
(i see pedals every day in our factory! mostly peugeot and renault)

 

[Echidna]

This is a brake pedal of my own design for the Locost seven i am building.

 

[Archie]

The quality of plasma cut parts is very good, provided you have a cutter with enough power. Be wary of the numbers given by the manufacturers as to how thick metal they will cut. Make sure the number you are looking at is the 'clean cut' and not the 'severance cut', which will be messy. Generally, I would say go for one with a bit more power than you need. Hypertherm are regarded to be the best make though they're not cheap. Some members have bought the cheapo Chinese ones off ebay and they aren't bad apparently though you shouldn't be disappointed if it breaks.

 

[Sam]

I cut mine using an aluminium template 4.5 mm undersize all around to allow for the dia. of the tip on the plasma.Any holes to be punched are transfered from the template and bored/punched after it has been cut, then I finish it off using a fibre disc on a hand grinder.You can see from the second photo you are able to get good results and fit if you take care making the template.