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Homemade Plasma Cutter (The Plasanator) Is Back

by jandgse812 on November 14, 2009

Table of Contents
License: Attribution Non-commercial Share Alike (by-nc-sa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intro: Homemade Plasma Cutter (The Plasanator) Is Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

step 1: Cutting Video of The Plasanator In Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

step 2: Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

step 3: Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

step 4: Parts View On Mounting Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

step 5: Board Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

step 6: Chevy Ignition Coil Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

step 7: Plasma Head Tip Wire Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

step 8: My New Plasanator Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

License: Attribution Non-commercial Share Alike (by-nc-sa)

Intro: Homemade Plasma Cutter (The Plasanator) Is Back
This Ebook is designed for Guys and Gals who like to create tools and machinery.

I hope my Ebook gives you hope that no matter how hard a project may seem, keep plugging away until you finish and you will succeed.
I spent 3 years putting this together and now finally all my hard work and research has paid off.
I studied diagrams from commercial venders, but to no luck. They tend to leave a lot out on purpose - so its hard to reproduce their design. Ive see
different attempts at people making their own on You Tube and other sites, but what a death trap. Messy water resistors and wiring like a darn Christmas
tree.
So I began reading books and articles on their workings and took my home schooled-knowledge of electronics to build my own plasma cutter. I was
determined; failure was not an option.

I started by collecting parts from old microwaves, stoves, water heaters, air conditioners, car parts and more in the hopes of creating a low budget way to
create a plasma cutter for myself. I mounted it all on a simple piece of scrap wood; well its scrap wood now. We, didnt need that table anyway (shhhhhhh
dont tell the wife).
Then one day it all came together. I hit the power switch, placed the head to the metal, started the arc, felt the air kick and then a second hard kick (the
current being drawn into play). Then BAM, it was slicing through quarter inch steel like a hot knife through butter.
How sweet it sounded! I felt the amazement of completing a project that I just couldnt let go of.
So, take your time, enjoy and be safe.
The Plasaman

http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

step 1: Cutting Video of The Plasanator In Action

Watch this Video of me cutting 1/8 inch thick steel drum to make a homemade sand blaster cabinet.
You can also go to my site to view me and my friend George Muscott cutting with our homemade cutters.
http://theplasmacutterman.com/

step 2: Parts List

Here Is a Picture of my Parts I used for my Plasma Cutter.

http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

step 3: Main Transformer

The main transformer is a step down 3kva 240 to 120 volt or can be used as a step up transformer by reversing it.

http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

step 4: Parts View On Mounting Board

Here is a picture of the Parts I used.
The fan is optional and I would only use it if I run it off 240 volts.

I run it off 120 and can cut up to 1/4 inch so thats good enough for

http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

me.

step 5: Board Completion

This is a shot of the completed set up of all my parts on board.

http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

step 6: Chevy Ignition Coil Assembly

Here Is How I Assembled a Chevy Ignition

Start System.

step 7: Plasma Head Tip Wire Assembly

Heres How I made the arc tip wire from a paper clip plastic tubing and heat shrink.

http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

Coil for High voltage Arc

step 8: My New Plasanator Video

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http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

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Comments
11 comments Add Comment

drludi says:

Nov 29, 2009. 5:45 AM REPLY

how to connect parts? same as older version?

twenglish1 says:

Nov 23, 2009. 7:14 PM REPLY

whats the best way to limit the current to the cutting head?

jandgse812 says:

Nov 24, 2009. 9:22 AM REPLY

its already done, the element is your resistor limit,.

It works perfect just the way it is.

jandgse812 says:

Nov 23, 2009. 8:17 PM REPLY

The water heater element is your load resistor and its only single phase, I just use 3 phase rectifier becuase thats what I had.

twenglish1 says:

Nov 23, 2009. 8:27 PM REPLY

ok, i have the DC power supply set up, all i need now is the cutting head(its on its way) and a load resistor

Old^n^Tired says:

Nov 20, 2009. 11:41 PM REPLY

It all looks interesting, but not everyone has 220 Volts available. I've been scouring the web looking for either an "On Board", or separate engine driven unit
that would use a couple of alternators. I only have a 5 Hp engine and a air brake compressor, (the compressor would would use about one horsepower), but
its already 3 phase, so that might be usable? I'm not an electronics, or electrical guru, but I can copy what other people do if they have good illustrations.
If you decide to do something like I suggest, I'll be one of the first to try it.
Thanks!

jandgse812 says:

Nov 21, 2009. 9:37 AM REPLY

It runs off 120 or 220 and your far from being the first.
Just go to my site and go into photo page and you can watch my buddy george use his.
http://theplasmacutterman.com/

Karroo Oakey says:

There's something wrong with your site I think. What exactly is a rotary phase inverter.

Nov 20, 2009. 7:36 AM REPLY

rotary

jandgse812 says:

Nov 20, 2009. 10:01 AM REPLY

Hi Karroo, what it does is convert single phase ac like whats in ones home to 3 phase ac to run your power equipment like lathes, mills and things of that
nature.
I checked site, seems to be ok, maybe a glitch.
If you anything else just give me a shout. Joe

twenglish1 says:

Nov 18, 2009. 5:01 PM REPLY

what are the specs on that transformer?

jandgse812 says:
Its in the book now with picture of transformer.
#kva step up step down 120/240

http://www.instructables.com/id/Homemade-Plasma-Cutter-The-Plasanator-Is-Back/

Nov 18, 2009. 10:25 PM REPLY