Welding Tips and Tricks

I have a job where I have to cut out several hundred of the same shapes. The job won't pay enough to justify buying a computer controlled plasma torch and the pieces need to be plasma cut because of the heat outline the torch will make ( it's an art thing). What I would normally do in this situation is cut a shape template out of hardboard (Masonite or MDF), clamp it to the steel and follow the template along with the torch. It works good, but each piece of hardboard is only good for a few cuts until it chars up from the heat and then I need a new template. I'll go broke on time and hardboard cutting new templates for every two pieces of steel....

So.... what would be a good material to use for templates? It needs to be at least 3/8ths of an inch thick, non conductive to electricity, able to take an intense amount of heat, and be easily cut with a bandsaw.


Thanks!
Other Steve

Shooting from the hip here... never tried.

Could some thick glass, water-jetted to the required shape for plasma cutting work?

It maybe possible to stack multiple layers (Epoxy) to get the required thickness if 3/8" not available and you would need to provide an exact template of what you want or a cad file for them to cut.

A thin pad of rubber could be used to allow a clamp to secure while cutting and you would need clean surfaces to prevent breaking.

Not very bandsaw friendly but just a thought.

Andy

I use highly conductive jigs for plasma all the time. No insulation, and no issues. I'll drag the tip directly against a stainless fence.

If your machine refuses to cooperate, you could make a metal jig with non-conductive, replaceable stand-off feet.

Steve S

I slip on the tig finger and go at it free hand. I would use a piece of wood, I use wood all the time for stuff, never had trouble with burning.

Couldn't you use the stuff that a Tig torch insulator is made of? I think it's call Derlin, it comes in sheets of all thicknesses.

Len


Sent from my iPhone using Tapatalk

Otto Nobedder wrote:I use highly conductive jigs for plasma all the time. No insulation, and no issues. I'll drag the tip directly against a stainless fence.

If your machine refuses to cooperate, you could make a metal jig with non-conductive, replaceable stand-off feet.

Steve S

I was also wondering about the non-conductive part since I drag along a piece of angle iron often.

But that's only on low, my high setting wouldn't allow that because it requires a stand-off. (Older Miller spectrum 700)

The use of a non-conductive layer, or feet, would work excellent for my machine on high. Thanks for the idea

You could use Teflon PTFE sheet plastic,
From McMaster-Carr:
"PTFE has a slippery surface and surpasses most plastics when it comes to chemical resistance and performance in extreme temperatures. It resists most solvents. This material is also an excellent electrical insulator and can be used outdoors."
Color: White, unless noted
Temperature Range: -350° to 500° F
Tensile Strength: Poor
Impact Strength: Good

A pantograph?

J1NGaZZkTn8

Best idea yet!

I like the pantograph idea!! Very nice.
-Jonathan

Negativ3, Top Suggestion! Thanks

That pantograph is awesome!

great tool very ingenious

If you need a lot cut you could also look at outsourcing to a company that has a CNC plasma table. But the pantograph is a great idea.

The pantograph is very cool! Great idea!!