I'm a stock removal guy. Not having a bandsaw yet, I use rotary tool with a fiberglass cut-off wheel to chunk off the big corners and do the main profile on the belt-grinder. Smaller contours get ground with a sanding drum mounted in the rotary tool, and really small details are shaped with files.
If you want a few that are all the same, talk to Dave at Great Lakes Waterjet. I've only had one batch cut by him, but they came out really nice and the cost was offset by what I saved on belts, time, etc. He will also do single pieces to your design.
Got a link, poco?
I think he meant the new attachment and cut off wheels for a rotary tool!!
Got a link, poco?
rock on, pugsrok! Wear your safety glasses or a face-shield when you use that thing. Do not direct the impressive blast of sparks towards the dirty-laundry pile.
Remember, Father's Day is comin' up in a couple months. Give your dad something you made, ball-game tickets or his favorite snack. NOT a tie.
Pugs I am looking forward to seeing what you do. If you have any question ask them. All of us here on KD would rather answer the same questions a hundred times than you thinking it has been answered and you can't find it. We are here to help you as much as you will let us.