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Plasma Cutter Guide Wheels
Topic Rating: 0Topic Rating: 0Topic Rating: 0Topic Rating: 0Topic Rating: 0 Topic Rating: 0 (0 votes) 
November 15, 2012
2:43 AM
Mtw fdu
Senior Member
Forum Posts: 413
Member Since:
April 27, 2011

I recently bought a plasma cutter and needed the wheels similar to what you would use with a oxy/acet kit.  So I decided to make 1 instead of buying 1.


I started off with a peice of ally shaft 60mm OD and 30mm long.  I machined 15mm down to 30mm and machined a hole to a size of 22mm.



I then made sure my cutter plastic shroud fitted properly.  A good fit.




I moved the peice to the mill and set it up in the vice so I could machine a groove about 1inch wide using a 1 inch end mill.  This is what I finished up with.



Happy with what I had done so far, I moved the peice into the rotary table and machined off all 4 sides so they were square.




Then trouble struck!!!  I machined a bit too big a cut and 1 side was ripped off with the end mill.




Now I have to start agian from scratch.  Stay tuned!!!


Mtw fdu.

November 15, 2012
3:02 PM
Mtw fdu
Senior Member
Forum Posts: 413
Member Since:
April 27, 2011

I had a second go and this is what I ended up with.  I decided to leave 2 sides round because it gave it a better look. 




I decided to put the whole plasma gun in the peice and check for fit and size etc.



There is ample room for the cutter to stick through the bottom side with enough room to see.  Next I will post more pics when I do the holes and also make up the wheels.


Mtw fdu.

November 15, 2012
11:10 PM
Mtw fdu
Senior Member
Forum Posts: 413
Member Since:
April 27, 2011

Back again guys and I have finished my guide wheels.  Here is a pic machining the wheels.



Here is a pic of everything made and all layed out on my bench ready for assembly.




Here is a pic of the whole thing along side the oxy/acet wheels.




And this final pic of it on my plasma cutter.




Mtw fdu.

November 23, 2012
1:56 PM
Forum Posts: 590
Member Since:
February 10, 2011

Good work. I'd prefer a means of keeping the wheels easily aligned, by a flat on the dowels, but with a 'hand' in it would be fine like this of course.

November 24, 2012
2:39 AM
Mtw fdu
Senior Member
Forum Posts: 413
Member Since:
April 27, 2011

Jerry, Thanks for the reply. 


If you look a couple pics up with the exploded parts ready for assembly, those little "axles" are put through the hole and are solid riveted in with a hammer.  They don't actually move at all.  I have left a little room(maybe .5mm) on the width of the wheel so it moves freely without actually turning.  It works really well.  They do not "wonder" at all.


Mtw fdu.

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