http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

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HOMEMADE PLASMA CUTTERby jandgse812 on January 4, 2009

Table of Contents

intro:   HOMEMADE PLASMA CUTTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 1:   tools I used to make it. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 2:   The Plasanator in Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 3:   Plasma cutter Video with mission impossible tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 4:   The "PLASANATOR" Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 5:   Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 6:   Time for lots of pictures, hold on to your seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 7:   Now for some real pictures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

step 8:   More Pictures to come . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

step 9:   And some more . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

step 10:   My Friend George Muscotts Own (Warp Drive) cutter video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

step 11:   Just looking around at the (PLASANATOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Customized Instructable T-shirts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

intro:  HOMEMADE PLASMA CUTTERI Have built a homemade plasma cutter for my shop and now you can.Check out all my pictures and videos and start building one for your shop right now.First things first.Like all welding equipment it can kill you if you don't pay attention to what you are doing, so be careful and double check everything, then do it again.I am not responsible for any injuriesor accidents that may happen.You can get most of your parts for free or very cheap off of old cars, stoves, furnaces,microwaves, dryers or any appliance that you have access too.I'm not saying to use your ladies things, if you do and you get caught, I'm looking the other way but will say a prayer for you.Turn on your speakers and watch my 1 minute video of my cutter melting steel like butter while listening to mission impossible tune.

step 1: tools I used to make it.Here is the tools I used to make it.Now the stand I made it on was welded but you can put all this in a wood box or even plastic if you dont have a welder.1. flaring tool for making head connection.2. Drill driver.3. screw driver flat tip and slotted.4. 1/4 nut driver.5. 6 inch Cresent wrenches.6. diaganol cutters.7. lug crimpers from auto zone.8. wire strippers.9. zip ties 8 inch.10. blue spade terminals, yellow rings and female terminals.11. sticky feet to anchor the wires to board.12. circular saw.13. tefplon tape for air fittings.

step 2: The Plasanator in Action

Video

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

Here is the Plasanator in action.

step 3: Plasma cutter Video with mission impossible tuneThis video is only one minute long so turn on your speakers and check it out melting steel like butter. Yea Baby !!!!

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

step 4: The "PLASANATOR" Parts ListParts List

1, 120/24 volt AC Transformer.1, 120/12 volt AC Transformer.1, Contactor switch 3 pole 40 to 50 amp 120 volt coil1, Solid state bridge rectifier 40 amps 400 volts1, Air Solinoid 220 volt2, Electric stove coils 8 inch1, 40 to 50 Amp double pole Circuit breaker from (Lowes) depends on box $151, 125 volt house hold switch,box and cover from (Lowes) $61, 3 inch computer fan from (Surplus Center.com) #16-1322 $83, 24 volt AC Relays from (Grainger.com) # 1N185 $9.20 each $27.601, Dr124 Control Module from (Auto zone) $22.001, Hei 12 volt ignition coil from (Auto zone) #cg39 $19.951, 12 inch female ends from (Auto zone) $31, Spark Plug of any type from (Auto zone) $21, Low voltage bridge rectifier from (Radio shack) #276-1185 $32, DC Capacitors 3900 mfd 400 vdcfrom (The Electro store.com) $12.95 each $25.901, Air filter/dryer/regulator combo from (Harbor frieght.com) $25.001, China head torch 80 amp http://stores.ebay.com/welder-shop_cutting-torch_W0QQcolZ4QQdirZ1QQfsubZ8130064QQftidZ2QQtZkm with shipping should be $100.001, Foot pedal from (Grainger.com) under foot pedal switch, choose one (491-s) $201, Box of Blue female spade terminals and yellow ring terminals from (Lowes) $101, One 6 inch work clamp like whats on jumper cable (Harbor frieght) $5''''

step 5: InstructionsOk, Some Notes:Hopefully who ever you are that is looking this over, has some electrical knowledge of sorts.At least be able to wire a switch so you can understand what�s going on here.

First off, the circuit breaker on my board is something I had, to dress it up some and you don�t need this type of breaker.If you want, just use the breaker in the parts list for your fusebox, which you might already be equipped with.

The ground doesn�t need to be ran through a fuse but you will need it connected to your board.

That�s another thing, connections, you can save a lot of money by just using old ? inch bolts with two nuts on them for wire main connections or any lead connection youcome across, I did in the beginning.

I have a picture for you to look at called terminal to show what I mean.

Also you can save half the cost if you would just look around for some of these parts in your own area.An old stove, (coils) old microwave/oven combo (heavy-duty power cord wire for main leads or dc side of board), old 12 volt charger for non-working cordless drill (12 volttransformer).

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

Do you have an old car? Or can you get to a junkyard? (Coil, wire for coil, GM control module, Spark plug.

If you just take your time you could find 80 percent of this stuff just like I did.

Now I�m just saying you could find this stuff but I don�t recommend building this at all, it�s for (EDUCATIONAL PURPOSES ONLY) and I�m not responsible for anyone thatgets hurt trying to build this.

Now the fittings you need to hook the plasma head to the filter is something you will have to put together (IN YOUR MIND, NOT FOR REAL) because what ever head youmay use can be different from mine.

If you come across part say like the contactor switch, you find one cheaper but the coil voltage is 24 volts rather than 120.No problem just tap into the 24 volt system and run that through the house switch rather than the 220, just email me with questions if you need to.

Here�s a big one, when I get done cutting my capacitors still are holding a charge even when I disconnect the power, I just take a large bleeder resistor or have used alsoany old choke coil.

Touch it across the negative and positive wires coming off the caps don�t worry about me it doesn�t make a boom like you think.

Now my rig you see was just for test purposes and to make it easy to change parts easily and quickly if I needed to.

I plan on mounting all my parts in a nice cabinet probably wood construction and put some wheels to move around a lot easier.

Hers something, most of the china torches main lead (electrode lead) is ran through the air hose, so the connection nut is your electrode or negative connection.

This means that you would have to connect the electrode cable to the air filter frame.

It�s a good thing your not gonna build this because it is not an isolated circuit like if it had a transformer so one would need to be careful around this unit.

That�s why I would mount in wood case instead of metal.About the computer fan, this is to cool the main bridge but it does�nt have to be 120 volt.If you have a 24 volt ac fan then just hook to 24 volt side instead of 120 and when breaker is on so will be fan.

When mounting the control module to a metal platt form don�t foreget to put the grease that comes with it to help cool it although it never gets hot for me.

Now that�s what I would do if this was for real and not just (Educational) if you know what I mean?

The way I would do this project is start with page 1 and complete it then so on till I�m done.

File Downloads

Notes for Plasanator.doc (36 KB)[NOTE: When saving, if you see .tmp as the file ext, rename it to 'Notes for Plasanator.doc']

step 6: Time for lots of pictures, hold on to your seats.Now you get tons of pictures and I will put a couple of videos on the end of this thing.You have your work cut out for you but its really easier than it looks just follow these first diagrams one by one and you will be done in a flash.

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

step 7: Now for some real picturesNow here is a bunch of real pictures and pay attention to the ones about connecting your plasma head its very imprtant.

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

step 8: More Pictures to comeHere are some more, don't go any place.

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

step 9: And some moreOh yea, I said more.

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

step 10: My Friend George Muscotts Own (Warp Drive) cutter videoHere is a friends cutter he made with my plans and he named his (The Warp Drive).I figured you wanted a break and the next video is of the plasanator on its test stand getting a good look at the parts in place.

step 11: Just looking around at the (PLASANATOR)heres a video of the plasanator on its test stand for you to look at.Enjoy my friends and have fun and be safe. Joe

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Comments50 comments Add Comment view all 77 comments

 samuelchrist says:  Jan 8, 2009. 3:13 PM  REPLYI am in australian we use 240 ac not 120v, what do i do just use 240 to 24v transformers,most of the rest i have worked out thanks.

 jandgse812 says:  Jan 8, 2009. 9:39 PM  REPLYyour 240 volt ac will split im sure just like ours and one leg of hot to ground will give you the 120 volt you need for low voltage transformers.

 teddlesruss says:  Jan 9, 2009. 3:02 AM  REPLYEeek! No! No! A thousand times no, it will not "split!" Be safe, talk to someone in Australia that's done something like this. Please. I don't want to readan obituary.

 jandgse812 says:  Jan 9, 2009. 8:25 AM  REPLYWell you will just have to use 240 volt to 12 and 24 volt transformers.Go to grainger.com to get them.

 macsimski says:  Jan 8, 2009. 11:22 PM  REPLYthat is not necessary so. here in Europe one wire of the 240 is always on gnd level, due to the 3 phase way of doing things. between phases lives400Volts, between phase and neutral lives 240volts.

 teddlesruss says:  Jan 9, 2009. 3:03 AM  REPLYWhat he said!

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

 Eternal_Tristan says:  Jan 8, 2009. 2:42 PM  REPLYWhat if you are a lady?

 strangebike says:  Jan 9, 2009. 6:04 AM  REPLYjudging from the picture I don't think he is. I apologise in advance if I'm wrong.

 jandgse812 says:  Jan 8, 2009. 9:40 PM  REPLYThen im sure it will be put together right Tristan.

 jonathan.jekir says:  Jan 8, 2009. 3:19 PM  REPLYfor the love of $DEITY don't run the ground wire through a circuit breaker...it *needs* to be able to push massive currents, just for a split second without everbeing interrupted; if it's interrupted say goodbye to half the protection the breaker gives youthat said, amazing feat of garage engineering.

 jandgse812 says:  Jan 8, 2009. 9:37 PM  REPLYThank you very much.

 monopole2 says:  Jan 8, 2009. 9:20 PM  REPLYJandgse812,How thick metals can you cut with that torch?Can you cut 7/8", if not, is it possible to size it up?and how many VA on the 12v and the 24v transformerthanks

 jandgse812 says:  Jan 8, 2009. 9:36 PM  REPLYat 50 amps you can cut near 3/4 thick steel and yes you can build for larger cuts.The 12 and 24 volt transformers should be from 2 to 3 amps, you dont need much just to operate relays and control module.

 ColeP says:  Jan 8, 2009. 8:21 AM  REPLYsorry man, I must be simple today or something, but I only see 50/60 Amp heads in 12 and 25 foot lengths.

Like So:http://cgi.ebay.com/sh-4-torch-for-Air-plasma-cutting-50-60-A-12-feet_W0QQitemZ130250565149QQihZ003QQcategoryZ113743QQtcZphotoQQcmdZViewItemQQ_trksidZp1742.m153.l1262

Is there a model number I can search for? The 50/60 Amp is the SH-4.They can't have sold out in 1 day I assume, so hopefully I'm just an idiot today, ha.

Thanks for your help, I'm heading down to autozone tonight for that control module, and I will send you some pictures when it is finished.

I voted for you, this is the best project. Good luck.

 jandgse812 says:  Jan 8, 2009. 12:14 PM  REPLYcolep when go into it,look to left and you will see 80 amp click on that and it will show the heads,and you can use a lesser head like 40/50 if you want.

 ColeP says:  Jan 8, 2009. 7:24 PM  REPLYexcellent! thanks a ton man, found it, am ordering tomorrow.

 cmikowsk says:  Jan 8, 2009. 10:09 AM  REPLYDo you have a full page schematic for the Plasanator? It's easier for me to grasp the operation. Thanks for the good work.

 jandgse812 says:  Jan 8, 2009. 10:49 AM  REPLYits there last one

 cmikowsk says:  Jan 8, 2009. 7:03 PM  REPLYSorry I'm a little slow, got it.

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

 cmikowsk says:  Jan 8, 2009. 2:46 PM  REPLY???? I don't understand.

 Ouroboros439 says:  Jan 8, 2009. 4:03 PM  REPLYJust wondering what is the thickest steel you can cut and what is the amp out put?

 maxpower49 says:  Jan 7, 2009. 12:57 PM  REPLYis this 110v or 220v

 jandgse812 says:  Jan 7, 2009. 9:34 PM  REPLY220 Maxpower49

 DeusXMachina says:  Jan 7, 2009. 12:19 PM  REPLYWhere did you get the 110A 800V rectifier?

 jandgse812 says:  Jan 7, 2009. 9:34 PM  REPLYthe electro store but it dont have to be that hi, it was just what I wanted.Just keep it about 20 amps higher than your gonna run and around 500 volts or higher would be great.

 alex-sharetskiy says:  Jan 7, 2009. 2:48 PM  REPLYprobably online...

 smellsofbikes says:  Jan 6, 2009. 8:57 PM  REPLYI've been looking at building a plasma cutter as well.The main thing that worries me about this design, and others like it that I've seen, is that it appears that the clamp and work are at -110V, which scares thedaylights out of me safety-wise. Am I wrong about this? It would be nice to find a way to make this work that has the workpiece at ground, and uses aswitching power supply to act as an isolater (since an isolating transformer is cost- and weight-prohibitive.)I really like your use of oven heater coils as cheap high-power current-limiting resistors: it beats the daylights out of winding nichrome wire around a brickand running water over them (which I've seen other people do.) It's also superb that you've found a source for reasonably priced plasma handpieces/cables:I couldn't find those anywhere. Thanks for posting this.

 jandgse812 says:  Jan 7, 2009. 9:31 PM  REPLYits around 240 and as in welding it doesnt matter which end is neg or postitive.I can switch my welder to reverse to change my clamp to either or depending on how I want to weld.And thank you.

 jandgse812 says:  Jan 7, 2009. 11:07 AM  REPLYYou could simply reverse the connections on the board to give neg to clamp and pos to head and also the arc connections as well.add a 7.5 kva transformer to input and its isolated, it just will be bigger heavier and costlier.

 smellsofbikes says:  Jan 7, 2009. 6:23 PM  REPLYI guess the isolation transformer is probably the best way. I've welded enough to come to the conclusion that having the work charged is a bad idea.(This implementation isn't terrible insofar as the contactors open it so it's not live except when you're cutting, but that's still *awfully* exciting.)

I've wondered for a while if I couldn't start the initial arc, on either a plasma or a TIG, with a piezo sparker a la my propane BBQ. We have one pulledapart at work as a type of EMI source and it throws a quite respectable spark, with a lot less effort than using a car spark coil/ignition unit.Unfortunately I haven't yet had time to try it out.

 jandgse812 says:  Jan 7, 2009. 9:32 PM  REPLYinteresting, id like to here how it goes.

 mackjr says:  Jan 7, 2009. 6:36 PM  REPLYlove the TF2 music

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

 jandgse812 says:  Jan 7, 2009. 9:28 PM  REPLYthank you Mackjr

 panstar1 says:  Jan 7, 2009. 3:17 AM  REPLYif i am reading this right ,your powering this thing direct from a 50 amp 220 volt power line from the main panel ? If this is true that could be very bad. if I wereyou I would not use it outside or near any damp ground ( utility or pole pigs are gouned to the earth) I am saying this b/c you have no isolation what so ever& most likely burn off a few fingers from the 50 amps 220 line !!! no resistors or stove elements can't isolate it plus it would be a good idea to put a emf filterjust in case any back feed should become large enough to burn out there brand new plasma wide screen tv ! suggest using a stick welder b/c of it's limitedinput ability ! but it is up to you ,most of the early tig welders were mostly an add on powered by a welder . for me though I find the project quite dangerous ,Iwould rather be zapped by something that limits power rather than full line current from the breaker box ! but really good project it just has a few kinks in it,BTW you might be able to use a MOV as a igniter , instead of a hei coil & a modual that some how operates on ac any with out any trigger pulses from arotor wheel. ok enough of this blab blab for now .

 tercero says:  Jan 7, 2009. 10:59 AM  REPLYPretty much what I was told. I searched for plans back in the fall for making my own plasma cutter and came across these very ones, and the forumfound on yahoo.Tom Caudle over at CNCZONE wrote a frank reply to my inquiry if this was safe to build and use. In his words "Plasma has lethal voltages even withouta transformer isolated primary. The workclamp on a cutting plasma is not at ground UNLESS you physically ground the table! You can get a nasty shockif you touch an earth ground and the ungrounded plasma table at the same time. The voltages are higher than TIG and MIG welding and there is plentyof current to kill. I know plasma cutters are expensive but building your own could result in heavy expenses to your family for the funeral. Half of thesecret to plasma is the structure of the torch (with the arc start method) and the safety and control electronics in the unit. All plasma torches and unitshave sensors that if you are changing consummables and accidently hit the torch button you don't fry yourself.

I have years of experience in power electronics design, high voltage systems and control electronics. I would not attempt the design my own plasmapower section.

TOM CAUDLEwww.CandCNC.com"

I got the same answer from weldingweb, Miller Welding discussion forum, http://www.mig-welding.co.ukThey all replied that I was taking a stupid chance building and using this. So. I left it. I want to go on to build new things. Not die by building unsafe ones.Oh well.

 jandgse812 says:  Jan 7, 2009. 10:00 AM  REPLYI appriciate your input. but would you weld something while standing in water? I wouldnt and with all welding equipment there is inherent danger in volvedthat can kill you.The breakers will blow fast if any thing goes wrong before any major problems.When I cut for 10 minutes straight it will blow my breaker on q.I just put a fan on it and now cut for 25 minutes before it gets to hot, then let it cool for a couple of minutes.As for as affecting anything in the house, short of pouring water on it while its in use, its not gonna happen.

 panstar1 says:  Jan 7, 2009. 11:06 PM  REPLYyour right about it affecting anything else I was thinking of switching power supply ,but I have to weld outside I have no choice if I wish to stay alivebecause of the smoke given off . In my job I did most of the electrical work wiring up condensing units or which ever ,I also installed many breakersand even I tread lightly when doing this. But all you have in your setup is the hope nothing shorts and you never come in contact with the torch end.Plus just being on grass can be enough , remember hydro is also grounds there system using grounding rods as well ! so even slightly damp ground& you kneeling on it could do it. Now I am not mister wizard i have done dumb things to. & I only have what I have learned in electronics & i havelearned 120 hurts and to stay away from it. so if I did build your unit which is a wonderful project that saves a few $1000 by not having to buy one ! Iwould use a transformer to limit the current to 50 amps and isolating it from the power system and you will only get zapped if you touch the groundlead of the cutter. now my first welder was one of those cheap 50 amp welder from the 70's they were use less for welding but you can still find them$20 i payed of from the garbage. 4 in series would be 200 volts @ you could still get 50 amps but now you have a limited input which saves moneyon wire and you won't be drawing so much from the breaker box. Plus you will now be able to move the unit farther then 3 feet. Now if all this makessense & helps good if not well lets hit that one up to being bad at writing comment and insomnia ,plus a few to many seizures from epilepsy !

 teeps says:  Jan 8, 2009. 7:40 PM  REPLYI think a ventilation system would be in order, no?

great instructable btw. stuff like this thrills me despite my complete lack of intention to attempt such a feat. really makes one wonder how manythings CAN'T be hacked together that normally cost oodles of money, though.

cheers

 jandgse812 says:  Jan 8, 2009. 7:18 AM  REPLYThank you for your input, also remember now that if you touch the tip of the torch you wont be touching the electrode because it is insulated fromthe tip and only transfers to the tip when you power the high voltage arc start and come in contact with the metal.I can see some folks get to relaxed around welding equipment after awhile or any power tool but its all about being safety conscience about whatwhere doing during these few minutes of operation.

http://www.instructables.com/id/HOMEMADE_PLASMA_CUTTER/

 Psycosisnine says:  Jan 6, 2009. 9:27 PM  REPLYI dont see any China Head torch 80amp on the link you have listed... can you link us with a different example ?

 jandgse812 says:  Jan 7, 2009. 10:05 AM  REPLYcheck your link for brackets at the end.Idont know why but some how brackts are on some peoples link and it dont work unless you take them off.I just tried link again and it works great and there is 80 amp heads available still.

 alexhalford says:  Jan 7, 2009. 9:32 AM  REPLYCould you use the power supply in a MIG welder (135 Amps give or take) to build this?

 jandgse812 says:  Jan 7, 2009. 10:03 AM  REPLYI havent tried that but I dont see why you couldnt

 waterppk says:  Jan 7, 2009. 9:21 AM  REPLYThat torch head looks exactly like the one here: Harbor Freight So it looks like it's a legitimate part. You can buy a full torch for $500 from them, but if youpicked up one of their 20% off coupons it'd be $400, fyi.

 jandgse812 says:  Jan 7, 2009. 9:52 AM  REPLYfyi i payed 30 bucks for torch head on ebay.you could buy one those china made junk boxes that the control boards are always going out on or one could take the american pride of building his ownand use parts that are cheap to replace.Also not everyone one has 4 or 5 hundred bucks lying around to buy one , but they do have used appliances everywhere.

 sensoryhouse says:  Jan 7, 2009. 1:23 AM  REPLYwho doesn't own a welder but builds their own plasma cutter?

 kiowamike says:  Jan 6, 2009. 7:14 PM  REPLYThanks a bunch one more question though, what kind of pressure does this machine require?

 jandgse812 says:  Jan 6, 2009. 8:09 PM  REPLYit runs great at 35 psi compressed air. and your welcome.

 DeusXMachina says:  Jan 6, 2009. 5:20 PM  REPLYWhat are the stove coils for? Are they just low-ohm high-current resistors?

Additionally, why do you care about charge being stored in your caps? It's only going to be used the next time you fire it up, and if you're not going to use itfor a while, they will bleed most of their charge over time.

 jandgse812 says:  Jan 6, 2009. 7:06 PM  REPLYyep and the caps are two fold, smoothing capacitors and they are set up as a voltage doubler system.

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