When I decided to do this, I intended it to be much larger. However, I decided to see how small I could get it without completely obliterating the details and this was the result. 

how did I make this? First, I found a clear picture of Mt Rushmore and copied it into XCS. I figured how many layers I would need. One for each face and then the background layer which included the alcove between Roosevelt and Lincoln. That is a total of 5 layers so I made 5 copies of the image. 

The first copy, I did an outline of the entire image and set it to 0.000 so that it lined up with the edge perfectly. I set the outline to red to represent the cut line. I then edited the image to erase everything except the alcove, leaving that as is with just a bit of Roosevelt and Licoln on either side for overlap. 

The next copy, I edited the image to remove the alcove and then did an outline again with the setting of 0.000 and changed that to red to represent the cutline. Then I opened edit again and removed all but Roosevelt. 

The third copy, I edited the image to remove Roosevelt and the alcove then, once more did an outline at 0.000 and changed it to red to represent the cutline. I then edited it to remove all but Lincoln and the rock just beneath Roosevelt.

The fourth image, I edited it to remove Lincoln, the rocks beneath Roosevelt, Roosevelt and the alcove. I once more did an outline and set that to the same as above, 0.000 and once more changed it to red to represent the cut line. Then editing that, I removed Washington so only Jefferson was left.

Finally, I removed all but Washington and an angled part of the rocks leading down and to the right and then outlined that with a 0.000 and changed it to the cutline color, red. 

I went back and selected each image and grayscaled it, increasing the brightness to the same amount on each of the 5 images. 

I grouped each one together with their respective cutlines and engraves so they can be moved around to align for cutting. Then, to keep all at the same ratio for size, I select all items together and decreased the size to where I was happy, which resulted in this mini Mount Rushmore. 

These settings are for the P2 on Birch from xTool. If using a different machine and/or different wood (even same wood from a different supplier) you may need to adjust your settings accordingly to achieve a satisfactory result. 

Being the size this is, details got lost the smaller I got. Going smaller, the decor was recognizable only as a silhouette. At this size, the image came out decent with all the presidents faces fairly clear. 

I did have to sand each piece to clear away overburn a bit but was happy with the way they turned out using the settings above. 

When you have engraved and cut out the pieces, you should have 5 layers as shown in the image attached to this step.

When assembling this piece, I put the 2p10 adhesive on the back of the piece being attached to the one below. (See photo 1) Then I put the pieces together and stood them up on end to help align the bottom perfectly, using my fingers to line up the sides. 2p10 gives you a few seconds of work time so you should be able to slide the pieces back and forth a bit. After you attach a piece, stand them up so that you can align each layer as you attach them. 

The order of assembly is:

Put Roosevelt on top of the alcove (the back piece)

Put Lincoln on top of the Roosevelt piece.

Put Jefferson on top of the Lincoln piece.

Finally put Washington on top of the Jefferson piece.

When complete and the adhesive has set, you can, if you want, apply a light finish of your choice to it. 

Put this item on display as a desk piece, shelf piece, or anywhere you think it will look good. 

Now you can say, you have your very own Mount Rushmore in your home.