New plasma cutter

[crazyal]

I've always wanted a plasma cutter but just didn't have enough projects to justify the cost of one that would cut what I would want. I wanted to be able to cut over 1" on occasion for things like tooth shanks on buckets, etc. Well after reading some of the posts here and over at the Pirate 4x4 forum and getting a feeling that Mark wasn't just a salesman who when asked a technical question would just give a canned standard answer I found myself at Everlast's website. The price was about half of what I expected and was low enough to justify jumping in.

 

[k0ua]

Let us know how it holds up, I too would love to have one, or perhaps one of the multiprocess machines. maybe someday:licking:
James K0UA

 

[crazyal]

So today UPS arrived with my PowerPlasma 60. I'll post pictures below as I upload them. I quicky connected a 50 amp plug, the one that looks like an over sized 110v plug and connected up the cables. The cutter came with a small in-line filter, one thing I would like to have seen is a bracket to mount it to the back of the cutter. Other than that with in a few minutes I was ready to cut.

I ran into a few problems though. First I didn't have anything I didn't mind cutting. I finally found an old flywheel that I had welded a pipe to so I could drive ground rods. It had been sitting outside for a few years and was kind of rusty. So I cleaned some of the rust off to get a good ground and I was ready. Well not really. My pressure regulator was/ is stuck. Mark has said that if you put a full 175 psi into the back of it you could blow off a line inside the cutter so I shut off the compressor at 95 psi. It's 33 degrees out so I didn't want to run my refrigerated water separator (don't think I needed to). So I was ready to go.

I guessed that the flywheel was 3/4" of an inch thick so I set the power to 50 and with all the messing around with the compressor I left the pressure at 75 (I remember reading Mark suggesting 60 to someone else but being a new toy I forgot to dial it down).

The next problem I ran into was the flywheel was very rusty and being new to cutting I wasn't very smooth. I found I was moving too fast then would have to wait for the arc to catch up to where I was. I'm sure it made the cut more rough than it would have been if I was smoother. As I got a feel for it I felt like I was doing better however after I stopped I was down to 60psi so it could have been the drop in pressure helped out too.

So as I was taking a few pictures I threw a tape measure on the flywheel and it turns out it's over 1 1/8" think. Now I'm left wondering how much better it would have cut at full power (60). Over all I'm very impressed. I can't answer long term durability since I've only used it for a couple of minutes but so far it's been more than I expected.

 

[crazyal]

 

[crazyal]

 

[crazyal]

 

[crazyal]

Until today the thickest thing I had ever cut with a plasma cutter was a bearing race that had fused itself onto a crankshaft. It was maybe 1/4". I did it at a friends shop with a small cutter so I didn't play with any of his settings. Now I'm lining up as many projects as I can think of but most will not happen until spring .

 

[Shield Arc]

crazyal I went to Everlast website, but didn't see it. Does that machine have a scarfing setting?

 

[crazyal]

crazyal I went to Everlast website, but didn't see it. Does that machine have a scarfing setting?

I don't know, lol. I haven't downloaded the manual yet. I know they say it will do a light gouge but having such little time on it I really haven't had time to explore it yet. I'm sure Mark would be able to answer easier.

 

[Shield Arc]

In a lot of ways I'd ratter use a plasma for scarfing than a carbon arc torch. A lot cleaner!
Only draw back is sometimes you can't get the plasma torch in where you can a carbon rod, but sometimes you have to use a lot of stick out with a carbon rod too.

 

[xr_guys]

Your gonna like it, making a I beam grader for my Excavator was pure fun. It blasted through half inch without pilot hole, simply amazing..!:shocked: In about an hour I have a very functional implement that works well. Great tools is the key.:thumbsup:2nd by creative mind.

 

[Mark @ Everlast]

Al,
Thanks for posting up this...Your error is our benefit.:laughing:
50 amps with 1 1/8? This is in keeping with our maximum severance rating at 60 amps. We rate quality cut at 7/8".

Frequently we have been accused by our competitors and by people that have never used our products (even here), of poor performance, over stating our units capacities etc.

Keep the air dry though. Is that tip after finishing the cut?

Like you said however, the clock starts now as to answering the question of time.

Thanks again for posting. The 60 is my favorite. Of course the 50 is a strong second.

To answer the scarfing/gouging setting, yes, it will. I'll admit it isn't as good as Hypertherms dedicated setting on their new units. But it does decently scarf down around 40-45 psi. We don't use "specialized" consumables for this and in doing so, it won't be as good as the Hypertherm. But I have gotten decent results.

 

[crazyal]

I assume when you talk about scarfing I assume that's gouging, am I correct? I did read the manual but the on line one is for the older version and things have changed a little. I'll have to pull apart that regulator again, it happened years ago, and clean it up to get it working right again. Until I do I'll probably not mess around with trying to gouge.

 

[Shield Arc]

You can use the plasma to slice right into a weld, right down to the fusion line.

 

[Mark @ Everlast]

Scarfing and gouging are the same basically. Scarfing is typically used for "gouging" out defects in areas of metal. Gouging is really the process used...or something like that. I am sure there are technical definition distinctions, but I use them in a similar context.

 

[crazyal]

I had a SkiDoo snow machine that had a bearing failure. They use two bearings on each side of the crankshaft. When I brought it to a snow machine shop their 40 ton press couldn't remove it. Until then they never had a problem removing bearings. I ended up, I'm guessing gouging, removing enough of the inner race in two spots so I could split it in two without damaging the crank. When I brought it back to the shop they were impressed and said they thought for sure I was going to be replacing that part of the crank.

 

[crazyal]

So I had some time to play with the plasma cutter a little more. First I had to clean my regulator and mount/ plumb my air drier. The in-line filter that comes with it didn't include the mounting bracket shown in the on-line manual. After looking through the consumables I found the bracket and the screws needed to install it (much different looking than the manual). I ended up installing a small regulator before the filter and it's set to 80 psi. I also replaced the push lock connectors for the air line between the filter and cutter with ones that are 90 degrees. When I get a chance I'll take a picture.

You can use the plasma to slice right into a weld, right down to the fusion line.

I tried doing this but quickly found the metal bracket that clips to the cup must be removed. First it makes it all but impossible to angle the torch and if you don't angle the torch molten metal flies out of the cut and will quickly wear the consumables. Secondly the wire is metal and the molten metal will fuse itself to it. I'm not sure exactly what the wire does, to me it seams like training wheels for a noob like me.

I was able to gouge quite deep but I didn't have time to weld two pieces of 1/4" steel together and then try to cut them apart. But with Temps hovering around 32 degrees it started getting a little cold. But now I have not a single piece of scrap steel left and lots of small pieces.

 

[kawman14733]

i always wanted one of them machines.. ya talked me into one now,,cool stuff:thumbsup:

 

[crazyal]

i always wanted one of them machines.. ya talked me into one now,,cool stuff:thumbsup:

You would think it's easy but there is some skill involved. Being able to move the torch at a nice smooth speed takes a little time to master and figuring out air pressure and power are also a learned skill. But over all it's a great way to cut metal fast.

 

[J_J]

What kind of air filtering are you using.

This is what I am using, a Motor Guard filter with a filter regulator, and the desiccant pellets air filter from HF.

http://www.harborfreight.com/air-tools/air-accessories/desiccant-air-dryer-97686.html