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Plasma Cutter Guide Wheels
November 15, 2012
2:43 AM
Mtw fdu
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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.

DSCF0309-2.JPG

 

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

 

DSCF0310-2.JPG

 

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.

DSCF0312-2.JPG

 

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.

 

DSCF0316-2.JPG

 

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

 

DSCF0317-2.JPG

 

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

 

Mtw fdu.

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November 15, 2012
3:02 PM
Mtw fdu
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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. 

 

DSCF0318.JPG

 

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

 

DSCF0319.JPG

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.

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November 15, 2012
11:10 PM
Mtw fdu
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Back again guys and I have finished my guide wheels.  Here is a pic machining the wheels.

DSCF0320.JPG

 

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

 

DSCF0322.JPG

 

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

 

DSCF0323.JPG

 

And this final pic of it on my plasma cutter.

 

DSCF0324.JPG

 

Mtw fdu.

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November 23, 2012
1:56 PM
Jerry
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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
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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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