I Hacked My Plasma Table with a Skateboard

[@TheFabricatorSeries]

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[@zeemanjr]

I need more please

[@Jdmorris143]

I am 100% down for more of this! Your excitement on this was made it better.

[@richardjones38]

Design engineer here . This is a really cool idea. I think the problem with your dxf profiles is that you created the cut line from the ID of the tube. I totally get why you'd want to do that. However, the tube circumference at the ID is smaller than at the OD, so when the tube rolls, it doesn't quite roll far enough. This is why you got the gape between the start and end of the initial cut (until you added the tangential overcut), and why the tube profile near the start and stop point looks distorted slightly (especially on the mitre joins). If you scale the dxf in whatever axis direction the tube rolls in, by tube OD / tube ID, it will stretch the shape you need at the ID to match the distance the OD rolls. The start and end of the cuts should then match up without having to rely on the tangential over cut, and elaving the exact shape you wanted at the ID. I hope that makes sense.

[@timblack33]

I like an engineer that speaks common sense. I was thinking about the ID vs OD just wasn’t smart enough to explain it. lol.

[@LiveOff-Road]

Seconded. Thats what I picked up on too. He mentioned when modeling that he was modeling off the tube ID. Nothing to add there... I will however add that generating your cut path off of either the ID or OD alone wont work so well (Its causing the problem mentioned in the video of the less than perfect joint fitment). I have a little experience designing tube joints for 2 axis laser cutting in a couple dIfferent CAD packages. Im not sure about Onshape, but when you are using the frame trim tool (I think thats what you called the tool) does it allow you to select the option to cut normal to a selected surface? If so, draw your tubes with correct ID/OD and when the cut tool operates normal to the tube surfaces (just as the plasma cutter in reality will do) it will automatically follow the ideal profile where the tubes meet. For an angled joint part of that path would follow the ID and part the OD. If normal to surface cutting isnt an option( maybe in another toolset outside of the "frame" tools) its a good bit more work to get this result. Oh, one other benefit to this process is that it eliminates the step of the fillet you had to add to get rid of the points. That result is automatic with the normal to surface cut.

[@ShanusPortellusVI]

My thoughts exactly.

[@ryanschmidt1437]

Also a "design engineer." I work at a combination machine and fabrication shop, and the fab shop is routinely asking me for saddle patterns. Simply scaling up the ID pattern in the radial dimension will probably do the trick, but I like to make certain by using a 3d sketch to project the inside profile onto the OD. The other problem I see is that sheetmetal software typically uses a K factor when making the flat pattern; by making the sheetmetal wrap the actual tube thickness, the flat pattern width winds up being the mean radius circumference of the tube (not the ID nor the OD, but halfway between). This is where the model has gone wonky. Make the sheetmetal thickness a few ten-thousandths at the od, and you won't have to scale it at all.

[@richardjones38]

@ryanschmidt1437 good point. I hadn't thought about the sheet metal bend allowance algorithm distorting the profile slightly too because nothing is actually being bent. If the software will allow it, what you suggest, saved as a custom bend allowance preset just for 'unrolling' tubes for this application sounds ideal.

[@carel91]

Man, You just saved me 1000$, because I am about to buy 4th axis for my plasma, and this idea changed the game, Thanks❤

[@TheFabricatorSeries]

Thanks! This cost me $42 and 6 hours of work (plus paying the camera guy).

[@carel91]

⁠how about to use quick release bolts (like on bicycles) on gantries? Or mount it dire to moving part with torch? Another thing is how to make it adjustable, if you want to cut bigger diameter whit just one pair of guides.

[@malharapte5989]

@@carel91 You'd just need to run it at a different height and scale the horizontal axis appropriately.

[@carel91]

@@malharapte5989yes but center of tube is shifted due to angle from pivot. Maybe instead of pivoting wheels from that angle, just screw them down by Z, That could work

[@jeremyhanna3852]

I wonder if you could mount the mig welder on there and weld round stuff thats challenging not pipe notch but like press fit shafts

[@edgar0517]

I’ve liked the no BS videos before, but lately there seems to be a very positive vibe and friendship that’s working on camera, just even the genuine laughs is in my opinion brilliant, well done, keep it up

[@Falcon1956ca]

I'm 68 years old. recently built my own CNC router and am building a plasma table This is freaking awesome !!! I have two C can shops, one for wood, one for metal. Thank You Keep it up.

[@losotech206]

That's frickin genius dude. So simple.

[@grippgoat]

I'm actually enjoying your banter with the camera person in these last few vids. Not sure if that was intended, but I think it adds to your vids.

[@thejollywrencher]

Reminds me of the good ole days of KZbin. Just guys building cool stuff in their garage.

[@projectbrewsky2048]

This is awesome and exactly the kind of innovation the industry needs! As soon as the video started and I saw the wheels my brain instantly put 2 and 2 together and had that epiphany. We often spend so much time overcomplicating an idea when sometimes the best results really are that simple. I foresee roll cage and tube chassis projects shaving off at least 25% of actual labor time

[@burtonr]

That's cool! I'd love to hear more about it, and how you could refine the model to a weld-ready notch. Keep 'em coming!

[@adithmart]

It is welcoming to see another THINKING OUT OF THE BOX. I do this same thing daily, welder, grinder, mill, CNC lathe. Every single work day. When I am not at work, ideas spontaneously concoct solutions for the next work day, as my mind runs this type of thing in the background of life.

[@austinburtch5972]

Heck yes!! I definitely want a follow up video!

[@benjamindover7050]

Sincerely glad you're so excited. Good for you.

[@mikebrown7324]

Your cut profile is the inner diameter of the tube. That's why you originally had leftover tab on the first cuts.

[@adamkirkham4628]

Agreed. The original profile used with the frame function should have been the OD of the tube. Then the direction needs to be inverted when converted to sheet metal. I have not used the sheet metal function in onshape, but I know in other programs you can specify if your base profile is to be the ID, OD, or the centerline of the bend. If this is the case, you just need to change it to use the profile as the ID.

[@villageblacksmith9982]

How is the zero set at the center of the pipe?

[@azrielakbar3415]

​@@villageblacksmith9982 you should calculate the center v roll same as center to nozel

[@sleepib]

I played around in FreeCAD a bit, and I think the best workflow is to extrude a cylinder the OD of the pipe that you don't want to notch, extrude a cylindrical surface the ID of the pipe you do want to notch, cut the second one using the first, 3d offset that surface by the wall thickness, cut it again if it's anything but 90 degrees, and then flatten the face using the curves workbench. This will account for your motion system mapping to the OD of the part, and the ID and OD driving the fit on opposite sides of the joint. Dunno how often it will be relevant, but the rolling inverts one axis, so some things may need to be mirrored in CAD.

[@ryanschmidt1437]

Good looking out for the mirrored cut pattern. About the only place it will get you in trouble is when you have a non-perpendicular lateral that doesn't intersect through the centerline of the main tube, usually with a smaller diameter tube on the branch.

[@Mark4star1]

Excellent result from such a simply alteration. Well done. I can use that technique on my CNC mimi-mill

[@FSP3]

This is awesome! I think the reason you’re not getting perfect fit is because you are cutting the OD profile of your tube. Try cutting the ID profile and you may get a better fit. That being said, some angles may cause larger gaps.

[@TimWelds]

Awesome! Love the simplicity.

[@scottcarr3264]

That was a very clever way of turning your Plasma Cutter into a tube notcher, just with Skate board wheels and some brackets, I like it. As you said, if the machine does 95 % of the Job and you only have to clean the ends to fit a bit better, then it's all good.

[@PaulStaples-h2f]

Wow out of the box thinking, just imagine how many titanium bikes you could roll cut, absolutly awsome, great video, yes i defintely want to see more like this.

[@custos3249]

Not half bad. I've seen a few versions of these things, and so long as you're working in a narrow range of pipe sizes for how you set this one up, they're perfectly fine. However, the farther you get from the optimal size, the farther the pipe moves off center from your cutter. Ideally, rather than pivoting on that bolt, you'd want the wheels to come straight down so no matter the size pipe, the center is aligned. But again, if you're only working with a narrow range or always remember to adjust your settings and set up, you're golden.

[@gorak9000]

Just make different wheel holders for different sized pipe. Or use a turnbuckle like adjustment to adjust both wheels relative to the center line

[@stevenclarke4228]

Fantastic!!! Consider overcentre springs or gas struts to easily pop the wheels up and down with your handle idea, and allow for different size tube.

[@Bionicnightmare]

That is extremely smart, I would have never thought of it rolling with friction to get that axis. Now you need to refine it so it has clearance from your other axis. Blows my mind!

[@DirtySideGetsDown]

As someone about to start building a JD's Garage plasma table I'd love to see this idea refined. Always cool to see out of the box thinking that saves money.

[@mattvelardes8072]

I think JD had/has something for this also??

[@aldodifilippo1713]

i work with the 18 year old that is part of the facebook group you talked about, he made the origional design with his 3d printer and dads plasma table and brought it to work where we gave tips on possible ways he could improve it... and now a couple weeks later here we are lmao pretty neat

[@kevinschilling6813]

Of course we what improvements you come up with to take this concept up a notch. You have a way of doing this the simplest way possible!!

[@tiboreeb5360]

Man that idea is so cool... now i want a plasma table even more than before... First little improvement that came in to my mind: You could implement a vaccuum hose at the back roler to suck the fumes out of the back end of the tube, so that the extractor still works with tube cutting :)

[@shawnlindemood6678]

On my mill, I keep lookin into a 4th axis but don't have a 4 axis controller. One work around is to have the 4th axis hardware and just use us the X (or Y) channel to run it. Temporarily making it more of a lathe. I love the skateboard workaround!

[@chesowen]

Hey man. Met you at the shop trying to buy gloves. You gave me a glove heat shield and we spoke about video production (I’m a current film maker, guy with the production van) just wanted to say, love your channels and your content! No bs. Love the ideas classes and production!

[@MyAvitech]

With a setup like that, you're not limited to just cutting notches. You could cut almost any kind of pattern into the pipe to make some sick custom parts. For example, imagine fabing some exhaust tips with flames or some other design pattern cut in the end.

[@NathanNostaw]

Super exciting. So many way of little tweaks to the set-up to make it more awesome. What a game changer for anyone with a plasma table. Now I need a plasma table.

[@LarryStrawson]

The enthusiasm seen and Fireball tool squares make me think a collab with Fireball Tools in the future is something I would love to see. Keep up the great work!

[@ItsRenderInnit]

At the base where it connects to the gantry you could use a couple of slots with some knobs or levers with etched lines for the height of different sized tubes.

[@rogerbarrett2237]

For production use, some cam lock levers would be great to make adjusting the position of the roller arm on the gantry quick and would use no tools while still being tight and rigid.

[@dennisthatcher4384]

Love this! Suggestion; replace the springs with double acting pneumatic cylinders, tied together you could open and close from control station and control clamping forces.

[@BangShiftVideo]

We love it! If you used perforated sheet, instead of the solid sheet metal, under the tubing would the downdraft fan pull enough air to keep the smoke down and still provide a stable base for the tubing to roll on? Might be worth a try. Keep it up, we love this stuff and so do our viewers on the site.

[@SomeTechGuy666]

10/10. Love it. Love all of it. Came for the idea, got the CAD lesson and the enthusiasm. Love how you show how things really work in the real world. I've needed something like this forever. Please make another video with the Disney version and show us everything you do to get "there".

[@charlesboyd4469]

Very cool! I work with Bend Tech sometimes, which will give you printable cutouts (2d wraps) for all your tube nodes. I imagine you could easily drop those flat files into your cutting sodtware to run. Saves all the initial design time, especially for already completed assemblies in Bend Tech. Your idea is brilliant, and kudos for being the first to make it reality. I think it would go hand in hand with the Bend Tech auto generated node wraps.

[@Yosser70]

Cool idea 👍🏻 Can do the same thing with roller attachment. Laser engravers have an attachment that plugs into one of the axis so they can engrave mugs etc. just need a stepper motor driving a belt that goes over the tube, and make a frame with your 4 wheels for the tube to roll in. So instead of the axis motor moving the tubes backwards and forwards, it’ll roll them in place on the frame and wheels. Also, Google tube notching calculator, theres a few online programs that will output a dfx file for notches, ready to load up and cut 👍🏻

[@MichaelKearsey]

Thanks Justin, Look forward to seeing where you can take this.

[@253fabrication]

I've had my torchmate over a decade. You will learn about the kerf and how to compansit your kerf. Awesome video! Just learn your table and how it cuts with new consumables/vs shitty ones.

[@CraigHollabaugh]

Thanks for the project Tony! One vote Yes for the follow-up cleverness.

[@theoriginalDirtybill]

you may have to adjust your tube diameter in your model to compensate for slippage in the drive system. i would program in some test cuts the are full circumference of the tube at 90°, make marks on the tube at the torch zero and where the tube touches the plate, run the program and see if you are getting a full 360° rotation out of the tube.

[@dack42]

Add a strip of thin rubber (bicycle inner tube) on the table between the two sets of wheels. That should cut down on any slippage.

[@JesseHires]

Looks like all you need is a bit more for kerf of the cut and they'd be a perfect fit. This is pretty awesome.

[@constantinosschinas4503]

If you use Rhinoceros you can use the Unroll Surface command. It will unroll it without any extra distortions like k-factor. Rolling slippage and angle (does it roll parallel with Y axis) may be issues as well.

[@jonlambert321]

Dude you've done what some of us have all dreamed of simplicity

[@thebigappler]

If you add a square hole on the side of the recieving tube and a tab on the notch, the two parts will line up to weld every time the same without a jig.

[@tna2me197]

I had a different plan to use a couple fixed castors. But I like this setup way better I think I can still make the castors work and they already have a frame to attach to

[@jimlarsson565]

Make sure you have your bend factors in Onshape set to one. That’s probably why you needed to extend the lead in/out.

[@snowfarmer69]

Thats pretty trick. Need some indexable adjustable levers from McMaster so you can quickly slide the roller brackets on the gantry for shorter or longer pieces

[@timburkey6123]

This is so impressive. Love your work, and I want to see more. I can't even imagine how much this can improve tube fabrication! Go for it.

[@SeabassEngineering]

This is awesome. In a way it would be good if you could make it leave a tab, like it was doing originally but smaller. That way the scraps of material wouldn't get in the way as they are cut off, and leave only minimal cleanup on the tube.

[@Mikefestiva]

Nice work! That’s really going to be a time saver for sure 👍 thanks for sharing this info!

[@chrisbrown2174]

Awesome idea 😎 I'm definitely stealing this for my Fastcut table... I cut my holes inside offset but add 0.040 in cad. Same for slot and tab... Gotta build in the wiggle room.

[@PoodlePuncher]

Suggestion: if you switch to a spring "over center", it will allow you to flip them up out of the way. This Old Tony recently did a nice video about Over Center Mechanisms.

[@carlosduarte2222]

There’s notching templates online, you can just trace that template for the DXF. Or you can make templates using BendTech software too

[@butter1leg]

Once i get my plasma set back up, I'm totally figuring this out! Would love to see more! I'm still learning 3d modeling on fusion.

[@byronwoolnough6941]

Fantastic use of available equipment and clever thinking. My brain is working overtime trying to figure if my Arcdroid could be utilized to achieve the same results.

[@HalfacreFabrications]

This is pretty sweet! Please do another one. I’m working ideas in my head for how I can build one for my shop Sabre

[@Killen_Monsters]

Do you need to roll the tube on plate? Along the edge of flat bar means less chance of junk interfering. Nice job, love the infectious enthusiasm.

[@danielharris6934]

Awesome. Could be great for coping railing pipe so I don’t need an iron worker or coping die mechanism. Needs a side stop though to but a tube into so there is no side movement in the rollers. Also would speed production. Side stop needs to fasten to table frame rails as to not move around in sheet grating

[@projectLSaudiA4]

This is soooo cool! Brilliant design, simple yet effective solution to an otherwise complicated problem.

[@fastandfun20043]

Loved this video Justin! You look back to your old self in this one back to the days of the 20 dollar weld made me xxx money. Love it! You could do a series just on that cad software, you make it look sooo easy!

[@minskmade]

great video. I have a cnc plasma table i have built. Its amazing how it inspires you to work in different ways, and think of fabricating in so many diff ways. Great vid. Great way of showing the thought process also.

[@Phabian_Phabrication]

I definitely recommend some BONES FULL CERAMIC BEARINGS. They’re skateboard bearings and will be a SWEET upgrade from those pos target chi-nuh bearings, sweet idea 🤝🏽

[@CrayFishHandMade]

Can't wait to see the follow up , plans & Designs for the Skate Roller attachment 2.0 & more

[@SWResto]

Loved seeing your ideas and progress, some real world application to follow would be fantastic!

[@bobross07]

Dude what?!?! That's killer! Great video bud!

[@brianmcmahon2216]

This is really cool. Excited to see how far you take this

[@jcarlile8279]

30:20 seeing someone this giddy in the shop reminds me of my first day in a fabrication shop. All the toys and possibilities.

[@alecgoldie]

Really want to see the refinement of this. Currently building a CNC router and plasma cutter so would love to see what changes you make.

[@NTK_FabWorks]

I feel like it should have some runners under just where the wheels are, like 1/4” x3 strips. That way if you’re cutting parts without tabs, the drop can fall into the cut table and not end up binding the tube from rolling. Also, then you only have 2 runners to worry about keeping clean from spatter to keep the tube rolling easily. This is 100% going to get implemented on my table at some point

[@TheUncleRuckus]

Super cool proof of concept with tons of potential!! 👍👍 On your next iteration you could do something like Kip Handles or even Knobs to adjust the position of the wheel guides along the gantry. I'd be down to see what your next version be built.

[@mumblbeebee6546]

Great fun, very exciting. Would very much love a follow-up!

[@nonyabidness5784]

This is awesome. Please do a follow up with your improvements and refinements

[@CF_Sapper]

The world absolutely needs more of this!

[@TaylorJenkins]

With a couple of bushings, you could easily use this concept to cut rectangular tubing as well.

[@jonnygalante3623]

dude this is awesome. Very cool to see you getting excited about figuring this out, and a great idea. i need to brush up on my cad skills and ill try to build this out.

[@ryanschmidt1437]

Well, now I'm going to have to consider designing and making something like this for our 10' x 20' ESAB table. I might finally get to get away from making paper templates for the guys in the fab shop, but that probably doesn't mean I'll be doing any less (CAD) work, especially since I'm also the one who programs the plasma table.

[@scottwolford2147]

Want to see more upgrades!!! I want to try this on my Langmuir table. I use sheetcam also.

[@andyb7754]

You make it look so easy and maybe it is for a young very smart guy like you, but for a real old guy like me it would drive me nuts trying to learn the CAD program (which I'm trying to do)!! Very, very nice informative video, thank you.

[@bobw222]

Oh hell yes, go for it. Just your enthusiasm is infective.

[@willsatterwhite4378]

Super clever, I'll have to make this a priority when our table is up and running. Thank you for sharing!

[@chuckster158]

For sheet metal there is nifty value called k factor tipically it is defaulted to .5 this represents a piont exactly half of the material thikness. If you change it 1 or .9999 it will calculate the flat to the O.D.

[@KevinMoyer]

I want to see ALL the refinement ideas & associated videos for this idea!!! Great job and great video. Thanks man.

[@StephenKirker]

Stretching your frame and learning is so empowering! Great stuff.

[@ericjon262]

Pretty sweet! I might need to explore this for my crappy plasma!

[@TomsDIYShop]

Awesome design and execution! Thank you for sharing your idea!

[@Ammoniummetavanadate]

Unbelievably cool, this is insanely simple and powerful

[@Odd_Redneck]

Notch to shabby 😂

[@tamberp]

oh that's nice! Even with needing to do a bit of finishing work by hand, that's doing *so much* of the heavy lifting!

[@tomtammybates1512]

16Pcs 1” Roller Ball Transfer Bearings, 360º Rotation Universal Ball Casters, 400Lbs Carbon Steel Round Ball Transfer Unit for Conveyor, Roller Stand Use these to make a mount too your Z axis it will hold the tube a still be able to slide along the tube .

[@davidcashin9194]

Have got to see more complex stuff on the cuts and shapes very cool.

[@QuervoShots]

Genius! I definitely want to see a followup.

[@Inifexu]

@TheFabricatorSeries Tip when exporting the dxf file from your cad program. Make sure to have the bendrule of the sheet metal part with the k-factor on 0 and not the usual default 0.44 As k-factor whould shrink the part in the direction of the bend Print it to scale on a paper and wrap it around the pipe to try it All these design engineers in the comments crack me up 😅

[@eskoven]

This is Super-COOL 👏!!! Would love to see what your next plans are.

[@wmose3694]

you might consider having a strip of say 1 by 1/4 or so that you line up under both sets of wheels to use like a track to roll the what you are cutting on less chance of having some spatter mess up the tubes ability to roll as well that way you dont have to have a nice clean sheet under your work

[@jamesbibler6492]

Thank you!!! Would love to see your complete mod, if you make any changes.

[@zackschumann5521]

NGL, the thumbnail and video title irked me, but this project is mega. This is the good stuff, right here.

[@dbayboyds409]

Awesome video. Love the problem solving and the excitement when you got it to work!