How to Cut Shapes Out of Metal Sheets

Step 1

Make a cardboard template of the shape you wish to cut.

Step 2

Place the shape template on the sheet metal and trace it with soapstone.

Step 3

Place the drag shield (the tip of the cutting apparatus) on the metal at the place you wish to begin cutting. Make sure the arc is directed straight down.

Step 4

Press the trigger. Allow two seconds of preflow air before the pilot arc starts. Move the torch across the metal at a consistent speed once the arc starts.

Step 5

Adjust the speed so the cutting sparks go through the metal and out the bottom of the cut. If you don not see sparks, you are not penetrating the metal.

Step 6

Achieve a finer cut by holding the tip of the torch about 1/8 inch from the surface of the work piece. The closer the torch is to the metal the finer the cut will be, and you will get a wider cut if you raise it away from the metal.

Step 7

Pause briefly at the end of the cut to sever the metal shape from the rest of the sheet.

References

• The Fabricator: Cut it Out: How Fabricators Use Plasma Cutters Everyday
• The Fabricator: Using a Handheld Plasma Cutter
• Miller Welds: A Plasma Cutting Guide (PDF-p. 7)

Show More

Tips

Routinely change the air filters on a plasma cutter.

Low air pressure leads to low performance. The Fabricator recommends setting the source gauge 30 to 40 PSI higher than the pressure gauge on the machine.

A plasma cutter will produce a post-flow of air for about 20 or 30 seconds in order to cool itself after the trigger has been released. You can, however, resume cutting even if the torch is in its cooling cycle. Just pull the trigger.

Show More

Warnings

Wear appropriate welding gear when using a plasma cutter.

Clear the workspace of anything even remotely flammable. This includes protecting your hair from stray sparks; wear a helmet with face protection.

Show More