Before designing and cutting many hours are spent with grinders, wire wheels, torches and scrapers removing the old marine paint. When they are ready for the design area they look like this.

I design by hand directly on the buoy with chalk and ink. Stencils are never used to assure that each Fireball is unique.

I cut the Fireballs with a freehand plasma torch. I do not use CNC machines, computers or water jets. Here are some images of me during the cutting process.

Cleaning the Fireball.

For Fireballs destined for a painted finish instead of the natural rust patina, the Fireball is suspended from the ceiling to assure even coats of primer and paint with no drips. This red paint is the primer.

This is my hubbie Jeff helping finish the fireballs. After I cut them he uses a wirewheel and grinder to smooth rough edges and remove extra soot and grime.

A Fireball painted flat black with high temperature woodstove paint waiting to dry.

All Fireballs get signed by me at the bottom with the plasma torch when they are finished.

Enjoy!