If you thought the benefits of a plasma cutter ended at the torch’s cutting tip, you’re in for a bit of a surprise. In this final installment of our yearlong Cliff’s Notes fabrication tips collaboration with Miller Electric Mfg. Co., we’ll examine a variety of above-and-beyond options only a Spectrum X-Treme machine(s) can offer.
For those semi-familiar with plasma cutters, you’ll definitely appreciate anything that can not only extend cutting tip life, but also aid in cutting straight lines and circles (and any other patterned/template shape for the most part). As you’re about to see, Miller accommodates both wide-range performance and consumable longevity with its line of plasma torch accessories. For starters, their standoff roller guide (PN 194 883) is perfect for doing exactly as its name suggests: providing a proper—and sustained—standoff distance between tip and cutting surface. The circle-cutting guide (PN 195 981) offers the same benefits as well as fine-tuned straight line and hole cutting (up to 12-inch diameter). Both guide attachments are multi-adjustable. Though not shown here, Miller also has a suction/magnetic pivot base (PN 195 979) for improved torch stability when used with the above-mentioned cutting guides.
Now we come to the part that many of you may not be familiar with: gouging. Miller’s Spectrum 625 X-Treme offers users the additional feature of metal gouging, something that many of us would greatly appreciate—though we’d be hard-pressed to admit it. (Who ever fesses up to poor welding? We just grind down the ugly beads, right?!) By using the appropriate gouge tip, the 625 has the ability of removing existing welds without seriously compromising the metal being held together. Try that with an acetylene torch or a grinder! As the accompanying photos will most definitely attest to, gouging is the only way to go for partial material removal.
On behalf of the folks at Miller, we hope you enjoyed Metal Shop, and if nothing else, learned a thing or two about metal fabrication and the advantages of Miller welders and plasma cutters.
Without the use of the correct...
Without the use of the correct standoff tip on your plasma torch, ensuring the tip stands “off” your cutting surface (not drag) can be rather daunting, to say the least. That is, unless you incorporate an attachment aid such as this standoff roller guide. Fully adjustable with sharp-edged wheels for precise travel, you won’t have to rely on your hands and eyes to do the walkin’ … er, cutting.
Miller’s circle-cutting guide...
Miller’s circle-cutting guide is not simply a fancier version of the standoff roller. Along with the ability to accurately cut circles up to 12 inches in diameter, it can perform a multitude of “guided” functions, including lines straight as an arrow.
The attachment can be used...
The attachment can be used with or without guide wheel(s). For larger circles, obviously, the wheels are necessary—but for smaller ones, especially in more confined areas, just the pivoting pointer will do.
The attachment can be used...
The attachment can be used with or without guide wheel(s). For larger circles, obviously, the wheels are necessary—but for smaller ones, especially in more confined areas, just the pivoting pointer will do.
Cutting straight lines with...
Cutting straight lines with the aid of a piece of metal or an actual straightedge works—as long as you maintain standoff distance, not to mention avoid severing your guide. Plus, if you don’t have a means in which to secure your metal/straightedge, you have to manually hold it in place.
The circle-cutting guide ensures...
The circle-cutting guide ensures both consistent standoff and accurate cutting with no additional items needed—mark or tape your line out, set the guide, and let your hand and torch do the rest.
When cutting with a plasma,...
When cutting with a plasma, you “pull” the torch and want the molten metal to spray through and beneath the material surface. When gouging, it’s the exact opposite; you “push” the torch and the resulting arc spray will flow out and off the material. Any remaining slag left over from gouging is easily knocked off.
Gouging—removing only a portion...
Gouging—removing only a portion of material rather than severing completely through—is an additional feature offered by the Spectrum 625 X-Treme, something you may want to consider if you’re prone to making not-so-pretty or insufficient welds.
Our test piece was almost...
Our test piece was almost too easy to tackle, so we looked for an existing weld to throw in the ring and offer a real challenge for the plasma cutter—like this bracket that’s been welded to a frame gusset … on both sides.
Note there are no sparks emitting...
Note there are no sparks emitting from the opposite side of the bracket (in both passes), which is evident the gouge tip is doing its job and only removing weld material. Not only do we want just the weld bead cut out, we want to maintain as much of the original surface material on the remaining gusset the bracket’s being dissected from …
… which is precisely what...
… which is precisely what we’ve achieved here. A few passes with a grinder and our gusset’s good as new(er)!