It may be [MakeItExtreme]’s most ambitious build to date. There are a lot of moving parts to this plasma cutter tubing notcher, but it ought to make a fine addition to the shop and open up a lot of fabrication possibilities.
We have to admit to a certain initial bafflement when watching the video below for the first time. We can usually see where [MakeItExtreme]’s builds are going right from the first pieces of stock that get cut, but the large tube with the pressed-in bearing had us scratching our heads. The plan soon became clear — a motorized horizontal rotary table with a hollow quill for the plasma torch leads. There’s a jig for holding the torch itself that can move in and out relative to the table. Cams made of tube sections can be bolted to a fixed platen; a cam follower rides on the cams and moves the torch in and out as the table rotates. This makes the cuts needed to properly fit tubes together — known as fish mouth cuts or saddle cuts. The cams can be removed for straight cuts, and the custom pipe vise can be adjusted to make miter cuts.
All in all a sturdy and versatile build that ought to enable tons of new projects, especially when teamed up with [MakeIt Extreme]’s recent roll bender.
Continue reading “Plasma Cutter Jig Notches Tubing Quickly and Cleanly”
What do you get when you combine an arc cigarette lighter and some scrap glass and metal? [NightHawkInLight] created a simple plasma cutter project along with some hot glue and a few simple tools.
If you aren’t a smoker, an arc lighter uses a high voltage spark to light the cigarette. He essentially cannibalizes it for use as a power supply. Any similar high-voltage power supply should work just as well. He also uses the same cigarette lighter power supply for an arc pen, that we covered earlier.
Continue reading “Mini Plasma Cutter”
The [Make It Extreme] team has been racking up the builds lately, and a lot of them are heavy with metalworking. When you’re doing that kind of work, and you put as much care into finishing your builds like they do, it’s a good idea to have access to a sandblaster. So naturally, they built a really nice one.
We’ve featured a couple of [Michalis Mavros] and team’s build recently; you’ll no doubt recall this viciously effective looking spot welder and a sketchy angle grinder cum belt sander. The sandblaster build, centered as it is around scrap propane tanks, has some lethal potential, but luckily the team displaced any remaining gas from the tanks with water before doing any cutting. The design allows for a lot of sand in the tanks, with plans to provide a recycling system for the grit, which is a nice touch. And it works great – they even used it to clean it up before final finishing in the trademark [Make It Extreme] green and black paint job.
What we really like about the video, though, is that it’s a high-speed lesson on metalworking techniques. There’s a ton to learn here about all the little tricks needed to bring a large-scale metalworking project to fruition. It also demonstrates that we really, truly need a plasma cutter and a metalworking lathe.
Continue reading “Propane Tanks Transformed Into Extreme Sandblaster”
If you are a Maker space or individual lucky enough to own a Plasma Cutter, this electric
protractor compass could be handy. The folks over at [MakeItExtreme] built this circle cutting tool to help cut circles and rings in thick metal sheets using their plasma cutter.
The whole thing is built around an electro-magnet, so the jig will only work with magnetic metals. There are not a lot of design details, but it’s possible to infer how to build one looking at the video and the photos on their blog. There’s a couple of nice hacks along the way. Since the electro-magnet is stationary while the rest of the jig rotates, the main mounting bolt had a hole drilled through it to help route the cable. The rotating
protractor arm is made from a slab of aluminium and holds all the other parts together – the drive motor, the central hub and the plasma head. The motor used appears to be a 60rpm AC synchro motor. These types usually have an RC phase shifting network between the two coils to allow direction reversal. Friction drive is used to rotate the jig, with the friction coming from a pair of rubber tube bands attached to the electro-magnet and the motor drive hub. The plasma head holder has a rod-end with a roller bearing attached, acting as a caster wheel, ensuring the arc gap is maintained as the jig rotates. A few switches to activate the electro-magnet, motor forward / reverse and plasma enable complete the setup.
Their blog, and YouTube channel has a lot of other interesting projects that they keep building. Check it out.
Continue reading “Electric Compass for a Plasma Cutter”
What hacker doesn’t want a plasma cutter? Even if you aren’t MacGyver, you can probably build this one in a few minutes using things you have on hand. The catch? You probably can’t cut anything more than tin foil with it, and it is probably more a carbon-air arc gouger (which uses plasma) than a true plasma cutter. Still, as [Little Shop of Physics] shows on the video, it does a fine job of slicing right through foil.
If you are like us, you are back now after getting four 9V batteries, some tin foil, a pencil lead, and some clip leads and trying it. If you have more self-restraint than we do, you might want to think about what you are going to put the tin foil over. In the video, they used a laundry basket and a rubber band, but anything that keeps the foil suspended would do the trick.
Although it isn’t really a practical plasma cutter, we were thinking about strapping something like this to a 3D printer and cutting foil stencils. The jagged edges on the video are, hopefully, more from being operated by hand and less from the jagged mini-lightning bolt vaporizing the foil.
Continue reading “Build a Baby Plasma Cutter–Right Now!”
If you have been wondering what it takes to build a CNC Plasma Cutter then get ready to look no further. [Desert Fabworks] has documented the trials and tribulations of their CNC Plasma Cutter build. Saying it is extremely detailed would be an understatement. They cover everything from choosing components to machine setup.
The group already had a CNC Plasma Cutter that they have outgrown. To justify the new purchase the replacement machine would have to have a few non-negotiable features: 4×8 ft cutting area, torch height control, water table, cutting up to 1/2″ steel and be easy to operate and maintain. For the frame and gantry, they settled on a Precision Plasma kit as they felt it was the best value that met their requirements. The electronics package was separate from the frame kit and was provided by CandCNC. Among other things, this package included the power supply, stepper motors, stepper drivers and the torch height controller. For the plasma cutter itself [Desert Fabworks] chose a Hypertherm Powermax65 which can cut up to an inch thick of mild steel and has swappable torches so the main unit can be used for both the CNC table and hand cuts.
Continue reading “CNC Plasma Cutter Build Presented In Excruciating Detail”
This desktop mill would be impressive coming from anyone, but we’re really excited that it was made as a high school project. [Praneet Narayan] built it during his design and technology class. As his build log shows, he worked with a range of different tools to make sure he had a rock-solid platform on which to mount the motors and cutting head.
The uprights of the frame are made from two steel plates. After hacking them to rough shape with a plasma cutter he finished the edges with a mill. The two parts were then tack welded together so that the mounting holes could be drilled in one step, ensuring alignment between the two sides. The rest of the frame parts are built from extruded rails but he did machine a set of mounting plates to pull it all together. You can see the finished machine milling a message in MDF in the clip after the break.
Continue reading “Desktop mill built as a high school project”