For those of us without plasma cutters, this is how I make tight curves in 16 gauge. I'm sure someone will tell me a better way. At least I hope so. I have 2 more to make. I could use a grinder for the outside curves but what the heck, I'm drilling anyway and I want to be precise.
Yeah I go through a few bits. But it works. The other two are almost done. I got lazy and cut the inside straight line with a grinder but still managed a precise cut. I love working with metal. (And wood and plastic and leather)