plasma cutting router

[moT]

Although I have been doing some welding for about 30 years, I am by trade a woodworker.
I took the plunge on a Spectrum 625 in Dec. (Merry Xmass to me!), and though I love the way it cuts, I was unhappy with my ability to follow patterns with it.
I have spent many, many hours producing wood parts from patterns with a double handle router, and I wondered it I could adapt this method to plasma cutting.
See attached (I hope!) image to see what I came up with. It is made up from junk I had laying around the shop. The base is cut from some old 5/16" steel, the torch clamp from 1" water pipe, and the handles are old glass door knobs. Underneath is a 1" o.d. pattern following collar.

[moT]

plasma router

Whew! It worked!
Here is some layout work for cutting a turbocharger exhaust flange from 3/8" 304 ss.
The pattern stock is "Pergo" laminate flooring.

[moT]

Here is the second (outside) cut being made on the flange.

[moT]

plasma router

Here is the finished flange blank, paper pattern, and turbo that it will bolt to.
Overall I'm very pleased with the result, I don't even want to think about how long those cuts would have taken with a saw!

[cope]

moT, that's an interesting set-up. The glass knobs are a nice touch; hope P-C doesn't come after you for patent infringement.

[Dave Haak]

moT,

Great idea! How do you hold the trigger and the two handles at the same time? Rubber band on the torch? Great edge on the 5/16" round base. I'm guessing rotary table and up against an end mill on a vertical mill??

Dave

[russell]

I can see where that would help keep the cut vertical,especially on thick pieces. But would be nice if you had a clearer view so you could also freehand cut.
I have thought of making one like a pin router,but you would have to move the metal instead of the torch,so it would`nt work except for small pieces.

[moT]

re: plasma router

Russell, I gave the overhead pin router idea some thought as well, but can't see how the pin can not be damaged by spray from cutter? The view of the cut is badly obscured so free hand cutting is not an option at this time. That's something I have to work on improving.
Dave, I planned to rig up some kind of linkage to allow torch control from the glass knob. I found though that if I clamp the torch so that the switch is right next to the knob I can work it with a finger while still gripping the knob with my right hand. The plate was cut out with the P torch, the center hole was cut out with a hole saw, and then the outside edge was cut on the lathe with the plate inside gripped with a three jaw chuck.

[Dave Haak]

moT,

Thanks. Lathe would work too. I thought it was a little better than just a circle cutter.

Dave

[ChadRat]

Very cool! I would like to see the bottom of your plasma router thingie.

[banzaitoyota]

MOT: you need to port that wastegate!!! What Boost are you planning to run?

BTW: 3/8" seems awefully thin, What EGT's are you running?
I have warped a 1/2" Thick plate before on my turbo. 321 or 347 would have been a better choice IMHO John

[moT]

turbo flange

John,
It's for a turbo diesel, 8 psi boost, no more then (I hope) 1100 F on egt gauge.
I'm more slow and calm then I am fast and furious.
Chadrat,
I took a shot of the botom of plate that showed the pattern follower guide, but it didn't turn out. I'll try to get another one and post it.

[moT]

Chadrat,
Here's a shot of the pattern following collar. It can be removed to allow free hand cutting.

[ChadRat]

moT,
I get it now. I was thinking it was one of those lil roller things underneath. Very cool tool! I need to get a plasma cutter. Maybe one of these days. I need a good excuse to convince the wife why I need it. I can see it now. wife: Why do ya need a plasma cutter? Me: to cut metal. wife: Well, don't you have enough things that cut metal? me: yes, but...

[ZACHV]

Originally posted by ChadRat
moT,
I get it now. I was thinking it was one of those lil roller things underneath. Very cool tool! I need to get a plasma cutter. Maybe one of these days. I need a good excuse to convince the wife why I need it. I can see it now. wife: Why do ya need a plasma cutter? Me: to cut metal. wife: Well, don't you have enough things that cut metal? me: yes, but...

Tell her that you will write her name in a piece of 1/4" with hearts around it. That should do it.