Plasma cutter vs Bandsaw

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Been eyeballin the plasma cutters for a while. Sure seems like a neat gadget to play with. But is it really worth it over a plain 'ol vertical bandsaw for light boat fabrication work (mods,not builds) on thin aluminum where time and production rate are not really big factors.? I know it can do some things ya can't really do well with a bandsaw, and the plasma cutters have real gadget appeal. Any real advantages either way.? Just kindof sittin onna fence over it and there's sure enough other items on the short list I know I'd get good use out of.. ..Lookin for some opinions to help me go one way or another.. Thanks..    d:^)  Schneeks..Last edited by Schneeky; 12-28-2010 at 10:24 PM.Reason: Cause I'm geezin again..ESAB 161 LTSCommunicate & adapt, diggit.?ΜΟΛΩΝ ΛΑΒΕ
Reply:The appeal of a plasma is not just gadget appeal...they are a very valuable tool.  Just like anything, if you need something more than your band saw for what you do then it may well be worth the investment but if it only has gadget appeal to you then you may want to spend your money elsewhere. I have one and I actually would get more use from a good band saw because most of my fab is angle, tube, channel, bar stock, etc.StephenMillermatic 251Miller Syncrowave 200Miller 30A SpoolgunHypertherm Powermax 30Etc., etc., etc.............Cancer Sucks!
Reply:I do exactly what you are speaking of (I primarily do repairs and full out mods on aluminum boats from small jon boats up to ~18' aluminum skiffs and the likes), and absolutely, positively couldn't live without a bandsaw.  I don't have a plasma, and am making money, so let that speak for itself, but if I lost my bandsaw, I would start searching for a replacement right then and there.  I'm sure the plasma would be much more efficient, for certain things, but it isn't a financially viable option for me, so I cope just fine without it.My main cutting tools for aluminum consist of:Vertical Bandsaw.7 1/4" Circular saw with 60 tooth blade.12" chop saw with 80 tooth blade.  Bigger is better with the bandsaws.  I have worked with a 14" saw for quite a few years now, and always managed to make it work.  I recently, however, acquired a 26", and am in the process of setting it up (customer work keeps getting in the way, but I'm absolutely not complaining), and I have many instances where it will be more practical.  I wouldn't ignore the possibility of converting a 'good' wood bandsaw.  I've done it with excellent results.  The 14" one I've been using is a 1940s - 1950s Delta, that was gotten off Craigslist for 100 bucks (which was before the goofy little Delta light that came with it was sold for 80 bucks on ebay).  Blade was slowed down with a 30:1 Ohio gear reducer (15 buck Craigslist find), replaced a couple old bearings, and it has been cutting daily for a few years now.  My 26" saw is a Crescent, made somewhere between 1912, and 1916, which sometime down the line was converted to metal cutting, by the use of a 60:1 Winsmith reducer, and replacing the babbit bearings with pillow blocks.  Someone also built a set of shrouds for it (I bought the saw from someone who bought out a closed down machine shop - I'm guessing the machine shop, or some fab shop built the shrouds, as they were done very professionally).  Saw came 3 phase (hence why I got it cheap), but seeing as it was belt driven, swapping the 1/2 horse 3 phase motor for a 3/4 horse Baldor (20 buck Craigslist find), will be a direct bolt on swap.  Aside from that, I'm just sprucing it up - replacing some guide bearings, new blade, and new tires.Who is John Galt?
Reply:Well I certainly learned something new.. Didn't know ya could change the speed on a set speed bandsaw like that.. I've got a coupla friends that have been trying to give me 2 decent bandsaws just to get them outta their shop. But they're setup for wood so I was checking elsewhere. Might hasta PM ya on that process if I don't get the 14" I bid on at an auction.. ..Tip'o'the hat to ya fer that little tidbit..    d:^)  Schneeks..ESAB 161 LTSCommunicate & adapt, diggit.?ΜΟΛΩΝ ΛΑΒΕ
Reply:For aluminum I prefer a saw or router. The plasma does a fair job but it can be tricky due to the way aluminum takes on heat. You can't really tell how hot it is... until it's too late. You have to go fast and be committed. My results with aluminum have been mixed. I find steel a lot easier
Reply:On the plus side for plasma - you can cut curves and multiple angles.On the minus side for plasma - you can cut curves and multiple angles.With a bandsaw you have - motor, gears, guides as 'serviceable' items and blades as consumables.With a plasma you have - air compressor, dryer, air lines, torch, power unit, ground clamp, etc.  and electrodes as consumables.
Reply:I have both and each one has its place. If you don't see the advantage of plasma, go with the bandsaw.
Reply:Plasma, at least the high quality brands should not be considered a gadget! Hypertherm sells thousands of plasma systems a month to industrial users worldwide....they are a valuable tool for a variety of cutting applications.I use a lot of rectangular tube in my shop....with wall thicknesses from 16 gauge to 1/2" thick. Often I have to cut angles up to 45 degrees on the tubing. A few years ago I bought a good quality horizontal band saw for this cutoff work. While it does a nice job....I often use the plasma to cut the 24' stock rather than the band saw. I built some cutting guides for the plasma torch that slip on over the tubing....drag the Hypertherm Powermax plasma next to the guide and I can cut these materials about 2 to 4 times faster with the plasma....and with the guide the cuts are very nice (not as pretty as the saw!) and with a quick touch up with the angle grinder are very high quality.A plasma with shielded consumables (such as Hypertherm Powermax45, 65, 85, 1650 units) work extremely well on aluminum.....can drag directly on the materials with no arcing, and will cut as well as a band saw once you get the hand of using the right nozzle and speed and amperage combination for the material you are cutting.Jim Colt
Reply:I would not want to be without either. Each has it's place.
Reply:if most of your work is with plate, go with a plasma.For everything else a bandsaw is more handy IMO.Buy American, or don't whine when you end up on the bread line.
Reply:Originally Posted by WeldingMachineif most of your work is with plate, go with a plasma.For everything else a bandsaw is more handy IMO.
Reply:if it's aluminum, i'd be thinking saws.  recently i had to cut four inches of some three/eigths plate the long way.  ten sheets each sheet eight feet long.  pulled out the cutmaster 51, dusted it off;  made a few stabs at it.  said screw it.  got out my o/a torch, put in a # 00 tip and away i went.  tip was 8.75 and i'm still using it.  plama setup app 16.00.  for me, i only use it to cut stainless steel sheet and plate;  and that is something i don't do on a regular basis.Last edited by fdcmiami; 12-29-2010 at 06:30 PM.
Reply:I have a vertical bandsaw, horizontal bandsaw, portaband, sawzall and a jigsaw all for saw cutting of metal.  In addition I have various air and electric cut off tools, chop saw, hand held electric shear as well as O/A cutting torches and motorized O/A cutting machine.I want to buy a plasma too but it will only augment, not replace any of the above. Mostly I expect it to save on O/A gas costs cutting plate more than anything else.Last edited by norite; 12-30-2010 at 02:21 AM.Reason: forgot to include sawzall"The reason we are here is that we are not all there"SA 200Idealarc TM 300 300MM 200MM 25130a SpoolgunPrecision Tig 375Invertec V350 ProSC-32 CS 12 Wire FeederOxweld/Purox O/AArcAirHypertherm Powermax 85LN25