My "Manumatic Non-CNC Plasma Cutter"

[Murfman1967]

Well I don't know about evryone else, but using my Plasma cutter, I cant cut a straight line to save my life. a straightedge is okay, and a CNC is not in my price range right now, so in the meantime I found this stuff:

http://8020.net/T-Slot-3.asp

This is what I ordered:

http://www.use-enco.com/CGI/INSRIT?PARTPG=INLMKD&PMPXNO=8915573&PMAKA=510-2059

http://www.use-enco.com/CGI/INSRIT?PARTPG=INLMKD&PMPXNO=8915532&PMAKA=510-2019

I also ordered a couple end caps, and some T-nuts to go with it. I made a recepticle to bolt to the linear guide that my Plasma torch fits into on my mill. It is aluminum, so I trimmed up some 20 ga stainless as a shiled for the rail and block. The T-slot is 97" long, so I can make an eight foot cut. The linear guide has nylon bearings, and rides very smoothly along the track. Here is a picture of what I have so far:
http://i184.photobucket.com/albums/x205/murfman_photo/DSC00656.jpg

I still need to finish my end blocks and alignment guides. The end blocks are 1/2" aluminum plate with 16 Ga alignment guides that will line up directly with the plane of cut of the plasma torch. I will be able to clamp the plates to the material I need to cut and zip away. The end blocks can be moved anywhere along the extrusion, so I can cut any length. I will get some more pics up asap.

[adampfisters]

Looks good, are you going to have anything to adjust the height that the torch will ride at?

[Murfman1967]

The hole in the guide is stepped, so the bottom diameter is a snug fit around the nozzle, I have it setup for 1/4" clearance between the bottom of the tip and the workpiece.

[Todd W]

The hole in the guide is stepped, so the bottom diameter is a snug fit around the nozzle, I have it setup for 1/4" clearance between the bottom of the tip and the workpiece.

1/4" between the tip and material will DRASTICALLY reduce your consumables and limit your ability to cut thick stuff UNLESS you are using a huge machine and cutting VERY thick stuff. Check in your manual for suggested cut height. Also the hypertherm company suggests 1.5 to 2 x the suggested cut height for the pierce height (if you are not starting on the edge).

-Todd

[Murfman1967]

1/4" between the tip and material will DRASTICALLY reduce your consumables and limit your ability to cut thick stuff UNLESS you are using a huge machine and cutting VERY thick stuff. Check in your manual for suggested cut height. Also the hypertherm company suggests 1.5 to 2 x the suggested cut height for the pierce height (if you are not starting on the edge).

-Todd

I am using a Lincoln 55 plasma cutter, and the 1/4" I came up with is about what the Drag Cup gives when it is installed. For piercing, I can hold the torch higher in the block to start my cut, but I usually start with a 1/8" hole if I'm cutting anything thicker than sheet metal.

[Todd W]

I am using a Lincoln 55 plasma cutter, and the 1/4" I came up with is about what the Drag Cup gives when it is installed. For piercing, I can hold the torch higher in the block to start my cut, but I usually start with a 1/8" hole if I'm cutting anything thicker than sheet metal.

Sounds like a plan. Get video of it inuse once done :)

[Burritoboi52120@aol.]

Sounds like a plan. Get video of it inuse once done :)

Definitely :smokin: I'm interested in seeing how this works for ya.


-Steve

[Murfman1967]

Well. UPS did not show up today with the "T-bolts", but I was able to finish up my bottom shield. I also need to go and raid the hardware bin at work for some SS allen head cap screws,as I ran out. The 1x1 Rail is suprisingly rigid over the 8' length. I'll be into this for < 70.00, ~ 2 hours putzing around and some scrap aluminum and stainless from my junkpile.

[Murfman1967]

Sorry 'bout the blurry pictures, guess I should have taken them BEFORE the Jack and Cokes:flipoff2:

http://i184.photobucket.com/albums/x205/murfman_photo/DSC00678.jpg

http://i184.photobucket.com/albums/x205/murfman_photo/DSC00676.jpg

I'll get some clear ones when I button her up:homer:

[Burritoboi52120@aol.]

Definitely a cool project in my opinion. Are you planning on making adjustable stops for it? Because if so you could do some pretty cool letter cutting with it :smokin:

-Steve

[Murfman1967]

Stops are no problem, the "T-bolts" can slide and lock at any position, they even have nice racheting handles for stops. I have a 5 x 5 welding table, and I have started to think with 2 more channels (one on each side of the table) and 2 more guides, I can move on both axis'. With stops on both directions, I'd have pretty steady control. I guess the next step would be stepper motors and a computer, but I digress.

I will be looking for a 8' ruler to add to the back side of the rail, along with a pointer (that is why I bought the dual flange guide, compared to the single)

[bggrnchvy]

Hrm, I too have been fighting manually cutting dead straight lines with the plasma. We have a fair amount of 80/20 extrusions laying around at work and I've got a package of 20 t-nuts for them sitting on my desk.

Oh boy:D

Thanks for a good idea!

[Murfman1967]

Well, I got it all finished up today, both feet are finished. The stainless pieces on the front of the feet are my guides, I am going to cut them with the plasma when I get my plasma back for work tomorrow. That way I can line op the "Guides" on my cut line, and make my cut. Obviously the cut will line up if the torch made the initial cut. here are the pics:

Side View:
http://i184.photobucket.com/albums/x205/murfman_photo/DSC00690.jpg

Bottom View:
http://i184.photobucket.com/albums/x205/murfman_photo/DSC00688.jpg

Torch Clearance:
http://i184.photobucket.com/albums/x205/murfman_photo/DSC00689.jpg

Foot with guide (still uncut):
http://i184.photobucket.com/albums/x205/murfman_photo/DSC00687.jpg

http://i184.photobucket.com/albums/x205/murfman_photo/DSC00686.jpg

[Burritoboi52120@aol.]

Looks cool, was really hoping for some pics of it in action though :D PLease post results once you get em.

-Steve

[Murfman1967]

Looks cool, was really hoping for some pics of it in action though :D PLease post results once you get em.

-Steve

Action Photos > me, I cant get any good ones of it in action, I can cut straight lines now though:flipoff2:

[Murfman1967]

Got some better pics:

http://i184.photobucket.com/albums/x205/murfman_photo/Tools/DSC00936.jpg

http://i184.photobucket.com/albums/x205/murfman_photo/Tools/DSC00935.jpg

http://i184.photobucket.com/albums/x205/murfman_photo/Tools/DSC00934.jpg

[THachiya]

Nice project!

Looking down from the top, you might want to scribe a reference line on the torch holder to help you "sight in" the cut line. If you made it a cross hatch, the "sight"' would also help locate the end of your linear travel when you weren't using stops.