Will a plasma cutter save me time?

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Over the next year, I will probably have to repair 500 racks, and I'm wondering if a plasma cutter will save me some grinding time as well as not using as many grinding wheels. I get a set amount per rack for the repair not per hour, so it's money in my pocket if I can do them faster. I'll post some pics of the work I will be doing so you will have a good idea if a plasma cutter is in my future.The first 2 photos show the bent piece of metal that has to be cut out. It's 1/8th thick.The next 2 show what it looks like after I cut the pieces out with my torch. Now the grinding starts. The slag needs to be removed so new metal can be welded in. Will a plasma cutter leave less slag? It takes me 2-3 mins per rack to grind the slag off.Miller 252Miller Bobcat 225Lincoln MigPak 1801959 Hyster forkliftHarris OA torch
Reply:I would go the plasma for that job. If the cuts are the same for each one then make a template / guide to make setup fast, you will need little or no grinding to remove the slag.Cheers Andrew
Reply:Getting clean cuts with plasma or OA are pretty much the same. You need your travel speed and heat settings to be correct to get clean nice cuts.The kids in the day program butcher material with both the plasma and OA torches. Number one they run way too slow with both. Number two they usually want to run with the machine cranked all the way up. With plasma the higher the amps, the faster you have to move to have a clean cut. It irritates the heck out of them when I walk over, turn the machine DOWN and make nice almost dross free cuts almost as fast as I can drag the torch across the material.I'd have to agree with a template and a plasma that is set right, you should be able to make very nice cuts with minimal cleanup. It would take me a bit to get the template right. I'd probably set it up so it slips into the pocket to line everything up, and have the depth set to my replacement stock size. Slap it in and bang out the three cuts in one motion and move on to the next one. Biggest issue would be the material that is turned up getting in the way of the torch tip. I might simply get a heavy piece of stock like channel and slide it in 1st and beat the metal down closer to flat so I didn't have that problem..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by DSWGetting clean cuts with plasma or OA are pretty much the same. You need your travel speed and heat settings to be correct to get clean nice cuts.
Reply:FODFA.......I free hand the 2 smaller cuts, but I have a piece of angle clamped to the forkhole and use it as a guide.DSW....If I have to bend the material back down, that's not going to save me any time.            Maybe a template that is larger than the piece to be cut out would work, and cut      inside the template instead of outside.Mick.... I'll look into the  Hypertherm 30Miller 252Miller Bobcat 225Lincoln MigPak 1801959 Hyster forkliftHarris OA torch
Reply:Plasma, hands down. What about adding angle end to end to help prevent this next time. Actually, if you fix it TOO GOOD there goes your money.
Reply:Originally Posted by WeldRite            Maybe a template that is larger than the piece to be cut out would work, and cut      inside the template instead of outside.
Reply:[QUOTE=Mick120;2425611]Looks like fork slots so, maybe not a good idea.Edit: My bad....already stated.The angle would go ABOVE the fork slots with Toe up. Angle would sit between what looks like 2'' x2'' square. Top of fork slot would have angle above it....
Reply:Flat bar is being used because if you notice, the black in the first 2 photos is velcro, and it needs to be replaced after the flat bar is welded in.Miller 252Miller Bobcat 225Lincoln MigPak 1801959 Hyster forkliftHarris OA torch
Reply:I don't understand why you cannot use a O/A torch unless there is an issue with heating up the surrounding surface.  If used with the proper tip and pressure, the cut will be just as clean and smooth as a handheld plasma.
Reply:Originally Posted by WeldRiteFlat bar is being used because if you notice, the black in the first 2 photos is velcro, and it needs to be replaced after the flat bar is welded in.
Reply:BD1....Sorry I'm not seeing it. I'm only doing what they requested. There are plastic parts slots that hang down and a door is held in place with the velcro.Miller 252Miller Bobcat 225Lincoln MigPak 1801959 Hyster forkliftHarris OA torch
Reply:I bought an eastwood(Chinese) machine last month and it lasted for 20  minutes.  That 20 minutes was like a whole new world.  It went through 3/4 inch like butter.  Having never pulled a plasma trigger, I was amazed at how much faster it was.  When it quit, I sent iT back and ordered tHe hyperTherm pm 30.  IT really struggled with the 3/4, but on what your cutting, it will cut as fast as you can move accurately, no slag once you get the hang of it. Having used OA torches for over 20 years, you will kick yourself for not having one 10 years ago.  I bought mine at welder source.com.  They had the cheapest prices by far over the rest. It arrived in 3 days.  Worked it for several hours straight the next Saturday with no issues.  I figure at least twice as fast.  My craftsman 30 gallon, 110 volt, compressor held up just fine.  the answer to your question is yes, it will save you time and make you money if you buy the right machine.  The votes for hypertherm are not a coincidence, but miller and thermal dynamics are probably just as good.  The hypertherm was priced between the two and I believe the thermal dyne smaller unit is imported.  I did not want to mess with another import.  The 30 will also run on 110 or 220 which was a plus for me.  I have not run it on 110 yet.Good luck.JayLast edited by Jayfarmlaw; 03-22-2013 at 10:47 AM.
Reply:Plasma will go quickly & when set right it's pretty clean. I'm not sure I wouldn't get some zip-disks (cut-off) wheels and give that a go first.The down side of the cut-offs are fatigue & danger from catch & bust.Matt
Reply:Originally Posted by WeldRite Maybe a template that is larger than the piece to be cut out would work, and cut inside the template instead of outside.
Reply:Crazy, I can't even see how you damage something like that.Plasma is nice as you can just let the button go and its off and does not go boom.You have to consider good  clean air into the buying price though and plenty of it.
Reply:It is clearly a good plasma application. The job will be about 50 times faster than using saws or abrasive discs, being aluminum there will be little heat input issues at the heats sinks away from the cut area rapidly. Powermax 30 would be perfect.  I have a 6 year old Powermax30 that is almost always used directly off a small compressor (3.8cfm, I get about 25 seconds of continuous cut then wait for it to recycle) for field jobs...never had a filter or moisture trap. I drain the compressor tank every use, on humid days sometimes a couple of times. As long as this is done you will not have a lot of issues caused by the air supply.....most users overkill their air treatment with many filters and dryers!Jim Colt   HyperthermLast edited by jimcolt; 03-24-2013 at 10:12 AM.
Reply:Don't forget that the Powermax30 is dual voltage. So if 220 volts is not available, both your plasma and compressor will happily run on 115volts. Perfect for portable work.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Originally Posted by jimcoltIt is clearly a good plasma application. The job will be about 50 times faster than using saws or abrasive discs, being aluminum there will be little heat input issues at the heats sinks away from the cut area rapidly. Powermax 30 would be perfect.  I have a 6 year old Powermax30 that is almost always used directly off a small compressor (3.8cfm, I get about 25 seconds of continuous cut then wait for it to recycle) for field jobs...never had a filter or moisture trap. I drain the compressor tank every use, on humid days sometimes a couple of times. As long as this is done you will not have a lot of issues caused by the air supply.....most users overkill their air treatment with many filters and dryers!Jim Colt   Hypertherm