My Dual Hose Reel Plasma Cutter Cart

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Using almost all of the remaining angle iron recycled from those three bed frames, I spent much of yesterday and today (we get Presidents Day off) putting together the much needed plasma cutter cart.  But not just your ordinary cart.  Building on an idea from another member (can't remember who and did a search but couldn't find it), the cart includes something special to make set up, operation and overall working conditions a more convenient.Got a ton of photos if you want to see more but I'm only going to put up 10 in two posts so stand by after the first post which is of the general fabrication.  Second post will be wrapping up the fab work and everything assembled and ready to go.  All external welds were ground smooth as I'm thinking of enclosing it with aluminum treadplate but for now it still needs to be blasted (out of blasting media), weld the shelf plates in place, painted and final assembled.  Don't know when I'll be able to get to that though so for now...Lower frame corner joint ready for weld up.Caster mount bolts welded to bottom of lower frame.  This will allow easier caster replacement if needed in the future.  Fourth bolt will be welded to bottom of lower shelf after blasting and final weld out.Rolling 'chassis'.Shot of the inner welds to comply with posting requirements.  All MIG'd with the MM200 and .030" wire, High 1, 40% wfs, C-25 @ 25cfh.Completed frame - almost.  More in post #2.Stand by for post #2.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Post #2.Took Judy out to see and and told her I still need to figure out a good handle.  She promply replied why don't you use that old mower handle?  Awesome idea and a perfect width fit!  Love you babe!!!Side view showing the 'Judy' handle and the special feature - dual air hose reels.  The reel on this side is equipped with a male quick coupler and facing the rear to plug into the air outlet or other shop reel.  Normal air inlet will be tee'd to feed the other reel......which is equipped with a typical female quick coupler and pointed forward to be used to operate air tools without having to run a second air hose.  For an extra outlet, the second reel air inlet will have a tee to accommodate another female outlet pointed rearward in the event an additional air line needs to be used.Rear view showing power cord and work ground cable as well as consumables tray.Thanks for looking.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Yep another bedframe bites the dust from duanne recyling. Gee now I know a use for those old mower handlesSome of my best projects use freebie bedframes. Great metal for most everything.Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:Took Judy out to see and and told her I still need to figure out a good handle. She promply replied why don't you use that old mower handle? Awesome idea and a perfect width fit! Love you babe!!!
Reply:great job why two air lines and not 1 air and 1 power cord reel
Reply:I also like the way the unit sis down into the carts platform without having to be strapped down as we have seen on a similiar cart. And the Judy Handle looks great. From now on  we'll have to call all cart handles "Judy Handles"Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:Originally Posted by ed macgreat job why two air lines and not 1 air and 1 power cord reel
Reply:Nice, very nice. I like the way you fitted the corner joint, I will have to remember that one.
Reply:looking good duaneLincoln 255XT Power Mig                                                                    Lincoln Precision Tig 225Hypertherm Powermax 30
Reply:Originally Posted by dakookNice, very nice. I like the way you fitted the corner joint, I will have to remember that one.
Reply:That really looks nice Duane.  I like the handle!!!!But...............................................  ...................Where's the cup holder??"Any day above ground is a good day"http://www.farmersamm.com/
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Reply:Looks good Duane! Gotta love those HF wheels to, those are the smoothest rolling one they have in that size. And they last longer than you would think, or they lasted longer than I thought they would (2+ years on a outdoor yard cart). Only thing I see that you need to add is one of those flexible shaft lights so you can see the consumables and use it as a head light as well. Good job welds look good too!Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Nice.  I like the fitup of the coped corners.
Reply:Very nice cart... Can I ask you, to explain in detail, what it is, you have connected to your air supply, on the plasma cutter.Thank you in advance.
Reply:Welcome to the forum Brian and thanks for the kind words.What you see there on the back of the cutter are two inline air filters that were installed by the original owner and as such came on the unit.  Good cutting performance and long consumables life depends on clean, dry air.  Someday I may exchange them for a single larger unit.DuaneMM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Hey DuaneI really don't know squat about plasma cutters.  If you used 02 would the thing try to weld, or just burn up the consumables, whatever they are."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Nope.  The four gases that I know of for plasma cutters are compressed air, nitrogen, argon and oxygen.  I'm sure there are others.The consumables are the electrode that is used to create the arc and the nozzle that directs the gas/plasma flow to the work piece.  The nozzles tend to erode quicker than the electrodes.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Sorry to ask such a stupid question.  I'll look the stuff up at a website.  I really need to get with the program on the newer stuff.  I really don't even know the principle behind these machines.Thanks"Any day above ground is a good day"http://www.farmersamm.com/
Reply:It's not a stupid question at all.  Although the plasma process has been around approximately 50 years, alot of folks still aren't familiar with it.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by farmersammSorry to ask such a stupid question.  I'll look the stuff up at a website.  I really need to get with the program on the newer stuff.  I really don't even know the principle behind these machines.Thanks
Reply:Duane,Very, nice indeed!  I didn't have any bedframes (meth-heads have stole most of them)??  so I modified a $49 HF mig cart for my Hypertherm PM-45.  I have been working on a 3 x 4 table so I can fab up a nice cart for my Dynasty (glad you guys keep building ahead of me so I can steal your inovations!)those Corners look awesome, I was going to just Mitre mine on the Cold saw, however your coping looks so much better!  The Lawn mower handle is trick (I think you should call it the "Love handle")Finally I see someone that has a table top as rusty as the one I just picked up (free)TimA rich man is not the one who has the most but instead one who needs theleast. Retired IUEC local 19AK Bush pilot,  Chaplain  CMA Chapt 26victor torchesMiller110v migDynasty 200dx (new in Dec 08)Hypertherm PM-45MM-252 (new 2/09)
Reply:Originally Posted by duaneb55It's not a stupid question at all.  Although the plasma process has been around approximately 50 years, alot of folks still aren't familiar with it.
Reply:The new 'Dual Hose Reel' plasma cutter cart in action.  Reel on this side is the 'supply' to the 350 plugged into the shop air and feeding the one on the other side which is for operating air tools and such (blow gun for this project) without having to drag out another hose.Shot of the air tubing from the rear.  In the event a second air hose is still needed, there's another outlet right in the middle tee'd in to the supply reel 'outlet'.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Nice job duaneb55I need to make one of those for my PM 600!#1. If you don't like what I wrote, or if it offends you, then don't read it!#2. I am living life the way I see fit, if you don't like the way I'M living, tough sh**!So you came out of the first reel, tee'd up to the plazma, over to the other reel plus an outlet??  Pretty snifty.
Reply:That's pretty much it in a nut shell Sandy.  I used it today for the first time since tubing it up last week and it was really nice not having to unhook the air from plasma cutter (requiring a restart) to use the blow gun or cutoff wheel.  Pick up is a snap too with the spring return reels.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Duane,I will keep an Eye out for the hose reel to go on sale at HF.  I am going to add a retractable Ground cable to my PM-45 as I can't stand the Hypertherm "stiff ground cable" (whats up with that)??TimA rich man is not the one who has the most but instead one who needs theleast. Retired IUEC local 19AK Bush pilot,  Chaplain  CMA Chapt 26victor torchesMiller110v migDynasty 200dx (new in Dec 08)Hypertherm PM-45MM-252 (new 2/09)
Reply:Neat solution having two rolls back to back. One question though, and it's more of a general question than one specific to your trolley; why do people never fit swivelling casters on all four corners? I got so fed up of having to carefully manoeuvre my welder I made up a new base with swivel casters on all corners so I could give it a shove in any direction!Lincoln CV400-ILorch T220
Reply:Good point!TimA rich man is not the one who has the most but instead one who needs theleast. Retired IUEC local 19AK Bush pilot,  Chaplain  CMA Chapt 26victor torchesMiller110v migDynasty 200dx (new in Dec 08)Hypertherm PM-45MM-252 (new 2/09)
Reply:Originally Posted by UltrachopI am going to add a retractable Ground cable to my PM-45 as I can't stand the Hypertherm "stiff ground cable" (whats up with that)??Tim
Reply:I found a set of locking swivels that where meant to go on a Craftsman bottom tool box that I am thinking of grabbing to use on mine when I build it!All four swivel casters can be locked, to make it a stationary stand!#1. If you don't like what I wrote, or if it offends you, then don't read it!#2. I am living life the way I see fit, if you don't like the way I'M living, tough sh**!
Reply:Ah yeah. I hadn't thought about how it'd move when you pull on the hose. You'd definitely want some sort of locking caster, swivel or not. The casters on my bench and on my welder (below) are all locking swivels though I don't think I've ever needed to lock the ones on the welder off! Last edited by Archie; 03-01-2009 at 12:12 PM.Lincoln CV400-ILorch T220
Reply:Originally Posted by Archie...though I don't think I've ever needed to lock the ones on the welder off!
Reply:Fair point!I'm afraid you've lost me on the regulator question though.Lincoln CV400-ILorch T220
Reply:Originally Posted by ArchieI'm afraid you've lost me on the regulator question though.
Reply:Oh you mean the guard round the valve! Sorry. I was being a bit dumb there! My cylinders are from a company called Air Products and all their cylinders have those and you're supposed to fit the regulator with them still on. The other company that supplies cylinders in the UK is BOC and theirs don't have the guard plus their valves face upwards. The reg in the pic is not strictly the right type for my bottle as the entry is in the bottom, not the side. That one would suit a BOC bottle rather than an Air Products one. Unnecessarily confusing, eh?! Lincoln CV400-ILorch T220
Reply:Originally Posted by ArchieOh you mean the guard round the valve!
Reply:BOC sells here in the US as well, but they do more servicing industry than anything, I wonder if Air products over there is tied in with Air gas here in the US!#1. If you don't like what I wrote, or if it offends you, then don't read it!#2. I am living life the way I see fit, if you don't like the way I'M living, tough sh**!