Homemade Plasma Cutter

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 2:   How a Plasma Cutter Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 3:   The Plasanator in Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 4:   Plasma cutter Video with mission impossible tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 5:   The "PLASANATOR" Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 6:   Instruction Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 7:   Time for lots of pictures, hold on to your seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

step 8:   Now for some real pictures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

step 9:   More Pictures to come . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

step 10:   And some more . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

step 11:   My Friend George Muscotts Own (Warp Drive) cutter video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

step 12:   Just looking around at the (PLASANATOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

step 13:   New One On The Way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Customized Instructable T-shirts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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.

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

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: How a Plasma Cutter WorksHow the Plasma Cutter works

The Plasma cutter uses two things, Air and Electricity.First the plasanator uses between 30 to 35 psi of compressed air.The air flows into the head and around the electrode through tiny holes in the swirl ring which capture and spin the air in a high speed vortex.Then the arc start circuit triggers and arc within this vortex and ionizes the air making it conductive, once this happens you now have a electricl short from the electrode tothe work piece.Then since you have this short, the main arc current is drawn from your DC circuit.The amount of current drawn is determined by your load coils resistance, and then you get a large arc fire with a kick of super sonic air blast which is converted toplasma, the fourth state of matter.This plasma is about 30,000 degrees F, hotter than the surface of the sun, and this is what blows holes in your steel like butter.I hope this helps.. Joe

step 3: The Plasanator in Action

Video

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

Here is the Plasanator in action.

step 4: 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 !!!!

step 5: 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''''

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

step 6: Instruction NotesOk, 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).

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.

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

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.

step 7: 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 8: 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 9: 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 10: 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 11: 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 12: 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

step 13: New One On The WayHere are some pictures of a not yet finished one using dc relays instead of ac relays.Circuitry the same except there is no breaker on board and dc relays. Enjoy

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

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Comments50 comments Add Comment view all 121 comments

 elb says:  Jan 13, 2009. 6:36 PM  REPLYHow complete is the schematic?

 elb says:  Jan 13, 2009. 6:35 PM  REPLYHow much is left to do on the step 13 version?Is this included in the plan set?Do the plans include the torch you built?

 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.

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

 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.

 darwinwandler says:  Jan 13, 2009. 5:22 PM  REPLYNO it will not split. Use 240 to 24 or 240 to 12 volt transformers. I am sure they are common in Australia.

 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.

 praxis180 says:  Jan 11, 2009. 8:58 PM  REPLYThe way power is supplied over here in Australia is that the mains coming into a home is 240V there are usually just TWO wires plus and earthwire (AKA single phase). These two are active and neutral (I think it's what has been referred to previously as ground). Occasionally a homemight have three phase, but in that case you have three wire plus earth, where two are 240V active and one neutral.....

 samuelchrist says:  Jan 12, 2009. 1:14 AM  REPLYyes here we do have what U say how ever the two coming in is Active an neutral the earth is a link the rod running from the ground, threephase is like u say but working in rotation red, blue and white plus neutral earth does not come in from the power pole ever...i installairconditioning systems for a living from small 1 kw units to 200 kws.

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

 hu008 says:  Jan 13, 2009. 11:52 AM  REPLYwow! pretty good. might try it.

 drboostv6 says:  Jan 13, 2009. 3:55 PM  REPLYThis has been done years ago... just a different resistor..http://www.youtube.com/watch?v=odgp-LkEzJ8&feature=channel_page

 drboostv6 says:  Jan 13, 2009. 3:54 PM  REPLYThis has been done years ago...different resistor...http://www.youtube.com/watch?v=odgp-LkEzJ8&feature=channel_page

 jandgse812 says:  Jan 13, 2009. 12:13 PM  REPLYwhy thank ya thank ya very much.

 undinstructable says:  Jan 13, 2009. 8:45 AM  REPLYCongratulations, man! Very interesting though I didn't get the whole picture... It would be nice attached to a CNC machine...Thanks for sharing!A

 jandgse812 says:  Jan 13, 2009. 10:39 AM  REPLYThank you, I think that would be cool too.Im gonna work on that next.

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

 jimwig says:  Jan 12, 2009. 10:22 AM  REPLYi have been cogitating about a plasma cutter for years.. i couldn't get a handle on the frequency part. but now there it is. i am so grateful. i will build this one.only in a higher power to cut 1/2 inch steel. (i hope)

right!!!! thanks again sir.

 jandgse812 says:  Jan 12, 2009. 10:42 AM  REPLYThanks Jimwig, add a couple of coils to reduce the resistance and it will cut 1/2 inch with know problem.

 jimwig says:  Jan 13, 2009. 9:37 AM  REPLYokay so now you know i sound good but that is about it.

tell me about the series coils. what are we talking in terms of size and inductance. i have some spike limiting coils from some stage theatricaldimmers. the dimmers went belly up sorta so the parts are available for this great attempt.

they were 2kw dimmers with the coils in series i think so number 12 wire on a laminated core. inductance i do not know.

if someone could verbalise theory of operation that sure would be swelll and excuse me if i missed same.

great project.

 panstar1 says:  Jan 7, 2009. 3:17 AM (removed by community request)

 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.

 bassbindevil says:  Jan 9, 2009. 11:10 PM  REPLYThere's at least one other person who'd agree. He built a DIY plasma cutter, forgot to power it off completely, then accidentally touched the tip. Whenhe regained consciousness, he was very badly burned and lucky just to be alive..

I really don't like the idea of the work clamp being hot. I'd hold out for some surplus transformer that can be rewound, maybe the transformer out ofan old arc or MIG welder if they aren't suitable as-is.

 drboostv6 says:  Jan 13, 2009. 7:13 AM  REPLYYou could get around that with a contactor activated by the trigger...

 drboostv6 says:  Jan 13, 2009. 7:11 AM  REPLYI'm currently building one...to get around these problems I'm using a huge isolation transformer, a contactor (activated by trigger also), and twoheavy duty carbon pile load (HD car battery load testers) (to control resistance)

 jandgse812 says:  Jan 10, 2009. 8:18 AM  REPLYits no different than with welding when you have the reverse polarity swtiched on, its the same thing and just as deadly.Welding and plasma cutteing is not a toy and if someone touches the tip while using it then he or she is just being careless, who would get thatclose to the tip anyway? I wouldnt and maybe thats why after about 500 cuts with it so far im still alive.Your bathroom recepticleby code should have a gfi in it but I wouldnt take a bath still while blow drying my hair niether.

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

 bassbindevil says:  Jan 10, 2009. 12:58 PM  REPLYWell, with most welders, reverse polarity maintains the work clamp at ground potential, and just changes the polarity of the electrode.Otherwise it wouldn't be possible to weld on large items which are at ground potential.

It's great if you can use it safely, but, $400 for a Harbor Freight unit is peanuts compared to the inconvenience of lawyers or medical bills ifsomething goes Horribly Wrong. You only need to turn your back on it for a moment with it hot for a friend/family member/pet to walk in andtouch something they shouldn't...

 jandgse812 says:  Jan 10, 2009. 1:36 PM  REPLYThats funny, my lincoln changes at the clamp, I guess anything in life can happen if your careless.

 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 (removed by community request)

 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.

 tsm3rdz says:  Jan 11, 2009. 9:31 AM  REPLYThis may be a stupid question but I've got an old lincoln stick welder (up to 225 amp)that I don't use since I got the mig. What are the chances as could usethis as my dc power supply? Than it would be isolated, correct? If so how would I go about adapting your plans to this old welder? Thanks in advance for youhelp

 jandgse812 says:  Jan 11, 2009. 10:25 AM  REPLYIts not a stupid question, interesting to say the least.I'm not sure but I am going to investigate this because I also wonder about that.

 tsm3rdz says:  Jan 11, 2009. 11:22 AM  REPLYGood deal! I will certainly keep checking back to this. What an ingenious thing you've done here. Very nice work!

 drboostv6 says:  Jan 13, 2009. 7:07 AM  REPLYprobably won't do it.. plasma cutters are high voltage/ low amperage - welder are the opposite.

 drboostv6 says:  Jan 13, 2009. 7:06 AM (removed by community request)

 jandgse812 says:  Jan 13, 2009. 10:31 AM  REPLYSorry but you really need to watch the video.It does work and its cutting like butter.The video says it all.The plasma is start with 40 thousand volts from the auto coil.You really dont know what your talking about.

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

 drboostv6 says:  Jan 13, 2009. 3:45 PM  REPLYWhats with all the negativity?

1. Sorry but you really need to watch the video.did

2. It does work and its cutting like butter.The video says it all.I didn't deny that.

3. The plasma is start with 40 thousand volts from the auto coil.Yeah - AC high voltage / high frequency - just as an arc starter.. the cutting is done in DC.. the AC overlay the DC only at the start.

4. You really dont know what your talking about.Wrong - you don't...a DC welder IS high amperage and low voltage...look into it.Plasma cutters use higher voltage and lower amperage.

 MetalMuncher says:  Jan 12, 2009. 11:09 AM  REPLYVery impressive.

 jandgse812 says:  Jan 12, 2009. 11:54 AM  REPLYThank you MetalMuncher

 jimwig says:  Jan 12, 2009. 10:36 AM  REPLYi too have a considerable experience in high voltage electricity. that's electricity not especially electronics. all that means is mains voltage.. if you build thisput it in an insulated enclosure. cool everthing well with fan(s) especially the series current limiting section aka the range coils --

build it a section at a time and test everything as you go. helpful would be a scope to look at the output waveforms - see what frequency is being generatedby the spark plug spark gap (a great idea).

and yes my all means write a theory of operation blog for those of us who would like to modify the design for different apps.

generally (with high voltage) one works with one hand behind him to keep from getting that CPR fatal jolt across the chest - from one shorted hand to thegrounded hand.

And i would suggest that whenever the unit is energized the operator (that's you all!!!) to do the same. it might save your life. and avoid that high funeralexpense alluded to elsewhere by a knowledgeable reader.

i am leaving out a lot but my brain is in dyslesxic mode, sorry.!

 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.

 bugmenot says:  Jan 11, 2009. 10:12 PM  REPLY35 PSI, but at what flow rate?

Thanks for posting this.

 v.johnraj says:  Jan 11, 2009. 2:03 PM  REPLYGood Work jandgse812 !!I have ordered for this spares, yet to receive couple of items.

 jandgse812 says:  Jan 11, 2009. 3:29 PM  REPLYthanks John, customs must be tuff over there?

 mmh says:  Jan 11, 2009. 8:19 AM  REPLYGood Instructable. You are "Armed & Dangerous" :)

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

 jandgse812 says:  Jan 11, 2009. 8:21 AM  REPLYI like living on the edge, kinda like how I sleep.

 Captainamer76 says:  Jan 10, 2009. 2:26 PM  REPLYNew to this. This looks amazing. You are a real go-getter. I would work on the safety issues posed. Just be careful. -p

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