Convert Your 4x4 to 4x8 With a PIPE CUTTER

[Joe Jones]

The 4x4 to 4x8 conversion to the table in Georgia worked out so well, that I have decided to offer the same conversion for other table owners. I have acquired several 4x4 tables from auctions lately.

Now, SOME of them will receive the grate elevator system, and that is a different topic. However, I have enough parts to convert several 4x4 tables to 4x8 tables with the rail extensions over the frame, which allows for pipe cutting without the need for the PlasmaCam pipe cutting attachment or the software, which means you do not need to purchase the $2,000.00 pipe cutting attachment from PlasmaCam. You will need to buy one additional gantry motor which PlasmaCam sells for $498.00. I have no control over that. This motor will be used to rotate the pipe or cylinder for cutting.

Some minor issues surfaced with the first conversion, but they do not affect the table's operation, and future conversions will take these point into account, making for a cleaner, easier installation.

I could register all of these tables into my name, but they are being cannibalized for parts, so why bother? Unless I fabricate them into fully functional, independent plasma tables with their own software license and controller box, they are just "so many parts." PlasmaCam wins because you will also buy their CSB (Customizable Size Upgrade) to run a 4x8 table, so they get a piece of the pie with each conversion, unless you already HAVE the CSB upgrade added to your DesignEdge license.

This extended rail configuration to create a pipe cutter off one end of the table is ALSO possible on the 510 tables. You have two choices ... Reconfigure the table to a 5x8 cut area with the pipe cutter overhang, or extend the rails beyond the 510 table to cut pipe beyond the original table frame.

Let me know if this interests you. I have lost of parts.

I STRONGLY advise people to ditch the PlasmaCam grate slats and change to a herringbone flat bar grate, which is more traditional, and far less annoying. As the weather warms up, I will begin to do these conversions at my shop and perhaps make some videos, and take some photos to show the process.

Joe

[sonbakler]

Pretty cool Joe. Do you have a pic of all the components you include in your 4x8 table expansion? What is the cost of your conversion kit?

[Joe Jones]

Pretty cool Joe. Do you have a pic of all the components you include in your 4x8 table expansion? What is the cost of your conversion kit?

I do not have a "kit." I take two of the 4x4 side frame angles and shorten them by twelve inches. ALIGN EVERYTHING! (Weld or Bolt) them together at the center. That scoots the legs in beneath the second full set of 4x4 rails by that distance, allowing the ends of the rails to hang over the far end of the table.

If you don't CARE that they don't match, you can use ANY angle that mimics the dimensions of the table frame. All you really need to convert a 4x4 to a 4x8 PlasmaCam table is:

(2) 4x4 rails
(2) 510 gear racks (important!)
(1) Swinging boom arm for the main wiring harness.
(1) Gantry or Carriage motor for the pipe cutter.
Assorted belts of various lengths, to turn different diameter ranges of tubing.

You CAN use 510 rails for extended length beyond the table frame, but then you need to use FOUR 510 gear racks to handle the rail lengths.

Once this is done, create a center cross brace and (Weld or Bolt) it into place. Check the distance between the rails at several points to make them parallel across the entire length of the two-rail set.

Fabricate two center legs that support the frame and rails at the butt joint of the two frame angles. Put adjustable feet on all six legs. A welded 3/4" NUT with a bolt through it, and the bolt head on the floor serves as a height adjuster to level the table.

The top corners of the PlasmaCam table legs must be cut off to allow the gantry to pass beyond the legs, and support brackets must be fabricated to support the rails from the bottom rather than from the inner faces as originally designed.

Fabricate new stops at the end of the rails, since there are no legs there to stop the gantry from falling out of the rails.

A swinging boom arm must be fabricated for the center leg on one side of the table, or you can use one from a 510 table, and cut the red tube a bit shorter, OR replace the top RED tube with the standard BLUE tube for the correct length. Be sure to space the vertical boom support AWAY from the rail by one inch or so, to insure that the gantry does not collide with the controller box as it passes.

Now get another gantry or carriage motor (it does not matter which one you get) and build some pipe rollers. Find a 9mm x 3mm pitch belt to rotate the pipe, and mount the motor to a pivot arm that allows you to take up the slack in the belt and put TENSION on the pipe, to rotate it as needed. The main wiring harness will be moved from the table's gantry motor to the pipe cutter motor for cutting pipe.

It really is a simple process.

The only thing is, you need to create a way to trip a limit switch when the pipe rotates, since the gantry does not return to a HOME position during initialization. You can use a rare earth magnet and a magnetic switch, so the pipe cutter AUX limit switch is tripped when the pipe rotates to a certain point. Or you can use a physical limit switch placed close to the pipe, with a stick on rubber "dot" to trip the limit switch when the pipe rotates to that point. Wire the AUX switch in parallel with the table's gantry limit switch.

rubber dots.jpg

With this dot in place, when the pipe rotates, the dot will trip the limit switch you choose. You do NOT need to use the same limit switch that the table uses. ANY switch with a NO/NC contact can be used. you only need to mimic the function of the original gantry limit switch.

Use more 4x4 table grate slate that are shortened, or ditch them altogether, and move to the herringbone 1/8" x 2" flat bar grate system, which is better.

Joe

[adbuch]

Pretty cool Joe. Do you have a pic of all the components you include in your 4x8 table expansion? What is the cost of your conversion kit?

This is a very popular conversion that has been done by many over the years. There is no kit required.

All you need to buy for the conversion is the two rails, an extra gear rack, and the customizable software - all available directly from Plasmacam. You will also need some 3/16” angle iron. Total cost including the Customizable Size upgrade ($998) is under $2k.

Conversion from the standard Plasmacam cutting grates to the upgraded version is simple to do. I'm pretty sure that Robert Johnson offers plans for the grates at his site.

David

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[Joe Jones]

A simple limit switch like this can be positioned to be triggered by an alligator clip attached to the edge of a cylinder. When the cylinder rotates to the "home" position, it triggers the limit switch in the same way the gantry limit switch is triggered by the leg it encounters during the INITIALIZATION process.

Joe

LIMIT SWITCH FOR PIPE CUTTER.jpg

pipe cutter alligator clip.jpg

[adbuch]

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[Joe Jones]

That looks nice, but what prevents the herringbone slats from sagging under weight? There is no vertical support down the center of the grates. I see no legs beneath the angles that position the slats. Two horizontal webs of the angle iron span the length of the table down the center, and two more closer to the sides, but the vertical webs are sliced for the slats. It appears that sagging is only resisted by the pinch of the vertical slats. This would be a nice design if the angle iron that retains the curved slats were supported from beneath via vertical legs that reach the floor every couple of feet. I suppose if you are only cutting sheet metal, it may not be much of an issue.

Joe

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