Plasma Cutter Buyer's Guide
4:55 pm in Articles, Home, News & Briefs, Special Features, Web Extras by bruce-smith
Custom Rigs’ 2010 Plasma Cutter Buyer’s Guide
Every custom fab shop needs a plasma cutter for speed, accuracy and creative curves. Our guide will help you find the right one at the right price…
By Larry D. Walton
When 4 State Truck’s Brian “Shaggy” Schwartz sets about to slip a set of headlights into the front bumper of a customer’s 379 Peterbilt, he side-steps the five-foot-tall roll-a-way with its assortment of grinders and metal cutting tools and reaches for the one tool he knows will quickly and cleanly cut out the openings he’s marked in the in the stainless steel: a plasma cutter.
Schwartz isn’t the first, nor will he be the last, custom rig builder to use electrons instead of muscle to cut shop time and improve productivity. Plasma cutters are the in tool, while hacksaws and cut-off saws are going the way of the Diamond T.
“Plasma cutting,” according to Lincoln Electric, “is ideal for cutting steel, and non-ferrous material less than 1 inch thick.”

Elizabeth Truck Center fabricator uses plasma cutter to customize headlight housing on a custom rig.
You can use plasma on bumpers, on taillight bars, frames, cab structures, exhaust systems and mirror brackets – just about anywhere where a hole saw, hacksaw, or cut-off saw is too slow or too awkward. Fast and clean, a plasma cutter could move to the top of your metal cutting tool wish list.
Plasma cutting conducts electricity from the torch to the work piece through a jet of ionized gas, usually compressed air. While the plasma heats the work piece, the high velocity of the gas blows away the molten metal creating the kerf or gap between the two sides.
Plasma cutters melt metals much like a welder does, but the process removes a thin strip of the molten material rather than crudely melting a big puddle of metal and blowing it apart as does the traditional cutting torch.
But the plasma cutter is much faster and simpler to use than the old-fashioned “hot-wrench.”
According to Miller, “Piercing, or creating a hole, can be performed by placing the torch at a 40-degree angle to the workpiece. Press the trigger.”
“When the cutting arc is initiated, bring the torch tip to a 90-degree angle and the arc will pierce the base metal. A good rule to follow is that you can pierce up to 1/2 of the maximum cutting thickness provided by the machine.”
There are a lot of plasma cutters on the market, so be a discerning buyer.
As with all of your treasured shop tools, look for capacity, performance, ease-of-use, reliability, portability, and value when looking for a plasma cutter.
When it comes to working on custom rigs, another item to look for is versatility. Quite often the cuts are on angles or require making clean, smooth holes — and some of the new plasma cutter technology is designed for exactly those purposes.
A Good ReadNEW PLASMA CUTTING TECHNOLOGY TAKES CARE OF THE “HOLE” ISSUE |
Many of the specifications to look for in a plasma cutter are much like welders: speed, duty cycle, power supply, weight and cost. Also compare different models for the types and thickness of material the machine can cut.
Advantages over Oxyfuel
While oxyfuel cutters such as oxyacetylene are limited to ferrous metals; plasma cutting can be performed on any type of conductive metal including mild steel, aluminum and stainless. Oxyfuel consumes compressed oxygen and a fuel gas where plasma cutters need only compressed air and an electrical power supply. Plasma tends to be faster, cleaner and is easier to learn than oxyfuel. Oxyfuel has its place, however, especially when cutting steel that is more than an inch thick or where electricity is not available.
|
Water Jet Cutters
ESAB’ set-up video includes some great instruction for using a plasma cutter: http://www.esabna.com/powercut/videos/setup/index.cfm http://www.kmtwaterjet.com/automotive.aspx
http://powerstreamindustries.com/
Speed Ratings Miller qualifies its cutting capabilities by a rated cutting capacity at approximately 10 in. per minute. You can increase your speed by using a machine with more amperage power. For example, Miller’s Spectrum 375 cuts 3/8 inch steel at 10 inches per minute while their Spectrum 875 can cut that same material at 41 inches per minute. |
MEET THE PLAYERS
ESAB
ESAB’s PowerCut lineup features an external housing design that is damage, corrosion and weather-resistant, while remaining lightweight for portability.
Also contributing to machine longevity are electronics, which are suspended from the aluminum frame to insulate them from shock and vibration. Sealed switches – silicone-sealed switches are immune to corrosion, as well as dust and dirt infiltration
PowerCut torch disconnects are tool-less and readouts showing pressure or amperage are of the large and digital variety.
Power input voltage selection can be made with a switch on the back of the machine. These ESAB machine automatically selects one of three modes: normal, grate and gouge. The gouge mode delivers the extra output voltage needed for the plasma gouging process.
The PoweCut 900 is rated to cut 7/8”, the 1300 cuts 1 ¼” and the 1600 cuts 1 ½”. http://www.esabna.com/powercut/models/
HOBART
Hobart’s AirForce 250ci Plasma Cutter features a built-in air compressor. It weighs only 28 pounds and is powered by 120 volt household current. A unique non-stick drag shield allows drag cutting without a standoff. Controlled pilot arc allows you to cut through grates, chain link fence & other perforated metals. It can cut through painted or coated surfaces without retriggering gun. http://www.hobartwelders.com/products/plasma/
HYPERTHERM
The Powermax 190c by Hypertherm is a compact unit with 1/8″ capacity and a built-in air compressor, which makes it ideal for portable use. Operating on 115 or 230 volt current, the machine’s output is 12 amps. Weight – 46 lbs. Comes with 20’ lead and spare consumables. http://www.hypertherm.com/en/Products_and_Services/Manual_Plasma/powermax190c.jsp
DAYTONA
The Power Plasma 3100 is the newest plasma cutter in the Daytona line-up. It can be plugged into 115V or 230V without flipping a switch. It weighs only 30 lbs. and can cut 3/8″ steel . http://store.daytonamig.com/powplas30.html
Daytona’s N250 is available in 110V version, which plugs in most anywhere and cuts up to 3/16″. The 220V version cuts up to 1/4″ comfortably. Each comes with torch, full set of consumables, ground, and power cables. http://store.daytonamig.com/
MILLER
Miller’s Spectrum®625 X-TREME™ weighs only 21lb but has a cut rating of 5/8 inch mild steel at 12 inches per minute and can cut ¼-steel at 60 inches per minute. Automatic Air Regulation automatically adjusts torch air pressure for optimum cutting and gouging performance, which eliminates the need to a pressure gauge or manual regulator knob on the unit.
Auto-Refire™ eliminates retriggering when cutting fences, grates and other expanded metal. Line voltage compensation provides rock-steady output even with fluctuations in input power.
The Miller Spectrum® 875 http://www.millerwelds.com/products/plasma/spectrum_875/ cuts up to 7/8″ mild steel . Miller says their “Ultra-Quick Connect™ torch and work cable offers the fastest plasma torch and work cable connection and removal in the industry.”
The unit automatically adjusts the air pressure to the torch for optimum cutting and gouging. The pilot arc switches in and out as fast as needed when cutting expanded metal and provides maximum power for cutting thicker metal. Auto Postflow calculates the length of postflow time based on the amount of cutting time to optimize consumable life. The cooling system operates only when needed, which reduces the amount of airborne dust/dirt pulled through the unit. http://www.millerwelds.com
THERMADYNE
Thermadyne’s Thermal Dynamics Cutmaster series ranges from the 39, which is rate for ¼” mild steel to the 152, which cuts 1 ¼ “. The series features microprocessor controlled front panel LED’s, a rugged roll bar for added durability, one set of consumable parts for the entire range of machines, lead extensions of up to 100’ and the flexibility to move quickly from hand to mechanized cutting with the change of a torch. http://www.thermadyne.com/thermaldynamics/
Thermadyne says their Thermal Dynamics AirCut 15c is “ready to cut right out of the box,” because of its built-in air compressor. This light weight, light duty (3/16 inch max.) machine can plug right into a single-phase 120 volt outlet, which means you can use it almost anywhere you can find power. Rated to cut 1/8 inch at 25 inches per minute, this machine is fast for its size. http://www.thermadyne.com/thermaldynamics/
Looking for good deals? Below are some of the e-tailers we found who sell ESAB, Thermadyne, Daytona, Miller and Spectrum. So check them out as you do your e-shopping price comparisons. –CR
E-STORES FOR WELDERS/CUTTERS |
|
• Versatile: Cuts any type of electrically conductive metals including aluminum, copper, brass and stainless steel. Useful for gouging and piercing as well. • Fast: up to 130 in. per minute on 1/4 in. steel • Quick starts: does not require a pre-heat cycle, which saves time • Precise: Produces a small kerf (width of the cut) •Protective: Has a smaller heat affected zone which prevents the area around the cut from warping and minimizes paint damage. |
![[13]plasmacuttingtruck_hi](http://www.customrigsmag.com/files/2010/02/13plasmacuttingtruck_hi-172x197-custom.jpg)



![Daytona Power Plasma 3100 [FPO]](http://www.customrigsmag.com/files/2010/02/Daytona-Power-Plasma-3100-FPO-107x131-custom.jpg)
![Miller Spectrum-875 [FPO]](http://www.customrigsmag.com/files/2010/02/Miller-Spectrum-875-FPO-154x128-custom.jpg)




















