Background:


I am designing a steel keel for a sailboat. I want to cut a hydrodynamic shape - an airfoil. I plan to do this as a 2D shape in plate steel. I am aiming for 1200 - 1500 lbs of steel, and *rough* dimensions of 90" (X) 8" (Y) and 4" - 8" thick (Z) It will be epoxy coated for corrosion resistance.

Obviously I'm thinking CNC plasma or oxy flame cutting.


I want to have this cut out (and maybe welded together if stacked) for a reasonable price. I could make this out of various combinations of steel thicknesses.


The question:


Any suggestions on thicknesses that are the least expensive to buy and cut?


I know plasma can go to 2" thick.


It seems plate steel over 6" is rare. 3" plate steel seems much more common. Is oxy cutting two 3" plates cheaper than one 6" plate for the same profile?


Should I limit the job to 2" so I can get quotes from shops that have either plasma or oxy flame?

Will the cost of the steel or the cost of the cutting dominate the total cost?


Thanks for any suggestions you can give!