Opinions on my Retrofit parts list for my 4X8 Water/downdraft table.

[PurposeBuilt]

Good day all you knowledgeable and awesome CNC and Plasma table DIY'ers! I'm super grateful I've stumbled upon this forum in my journey to piecing together my first plasma table.

I'm in the process of retrofitting my open-ended CNC plasma table and would love your input on the component list I’ve put together. My goal is to build a reliable, efficient, and clean setup with a focus on component compatibility and future-proofing.

This unique table was purchased new, used twice and neatly packed away and never used its entire life until I stumbled upon it. A few neat features is that it's not only a water table but also has down draft!! and it is open end gantry for easy loading.

Here’s a breakdown of the retrofit components I’ve selected, organized by system, what are your thoughts?

I’d really appreciate any feedback, suggestions, or gotchas you think I should be aware of before I get too deep into wiring and final assembly. If anyone has experience with similar setups—especially Masso + Leadshine + Hypertherm—I’d love to hear how yours turned out.

Pics of the table at the bottom.


Controller & Logic Power
Masso G3 CNC Controller

Masso 24V 3.2A Logic Power Supply
Masso Pendant (Wish I could go wireless XboX controller, but its not native to Masso)

Z-Axis & Torch Height Control
Karvecut Torch Lifter (motorized Z-axis)

NEMA 23 Stepper Motor – 425 oz-in, 4.2A (Z-axis)

Crash-Sensing Torch Mount with magnetic breakaway as a back up for piece of mind.

(Still sourcing): Interface cable for THC and Z-axis connection to Masso.

Motion System (Motors & Drivers)
Y-Axis Stepper Motor: 1200 oz-in (existing, staying in place)

X-Axis Stepper Motor: Existing (remaining as-is)

Z-Axis Stepper Motor: New (NEMA 23, 425 oz-in with brake)

Drivers (all Leadshine):

DM860T – Y-axis high-torque motor

DM542T – X-axis 4.2A motor

DM542T – Z-axis 4.2A motor

(Still to finalize): Power supply for stepper motors (properly sized for all three axes)

Plasma Cutter Integration
Hypertherm Powermax 1000 G3 (CNC-ready)

Duramax Retrofit Machine Torch

(Still needed): CNC interface cable (to connect torch-on, arc-ok, voltage signals to Masso)

Wiring, Panel & Safety
Custom Control Enclosure (to house electronics)

E-Stop Button and Safety Relays

Limit/Home Switches (X, Y, Z – for homing and safety)

Shielded Signal Cables

Ferrules, DIN rails, labeled connectors

Honestly haven't figured out a one stop shop or close to it place to get all the fuses, bus bar type stuff and grounding parts yet. Still learning about everything that I'll need.

Optional / Future Add-ons

Water mist secondary.

Water table control (solenoid valve, float switch, drain pump, etc.)

Thanks in advance!

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[weldguy]

Welcome! Interesting looking machine I have not seen before, looks well built.

Is it cutting now? Why are you looking to replace the CNC controller? If it's moving and cutting I would leave it!

The old 1000 is a great plasma cutter and with the Duramax torch you have a winner for sure. Just impossible to get parts for the 1000 if you need but definately run it through it's life, could last a very long time.

Not sure the water mist is needed but maybe you have something in mind for it. The downdraft is awesome and I prefer that over a water table with the only downside being heat loss out of your shop on those cold Calgary days.

Anyway, curious to hear how the machine is working for you right now.

[adbuch]

It looks like you are on the right track! Please keep us posted as you progress.
David

[PurposeBuilt]

Welcome! Interesting looking machine I have not seen before, looks well built.
Thanks! I thought so too... it is very well built in my opinion. I had a long winded conversation with Fab Cut Systems here in Ontario, Canada. The owner Rene knew the owner and builder of these machines back when they were being built here in Calgary, AB. He said they were a very high quality machine for their time with some fun options as you see mine has both down draft, water table and open ended gantry, Its very rigid so well se how that goes when I'm pushing the machine at higher speeds.

Is it cutting now? Why are you looking to replace the CNC controller? If it's moving and cutting I would leave it!
Technically yes it could cut now. If I were to source an older windows computer and try to get it running on Mach3 again with the right connections. But the computer it came with is a brand new windows unit with windows 10 and the breakout board that is native to this machine has a parallel port. Newer computers don't even have a real parallel ports, and USB-to-parallel adapters will not work for Mach3 control. A must have for me is the THC and crash detection features. This automatically put me into replacing the controller. The THC will require me changing out the manual lifter for an automatic set up and adding more power, driver, stepper ect ect. So here I am this deep into the retrofit that in my personal opinion it just makes sense to follow through with the other drivers, relay set up for peripherals and so on.

The old 1000 is a great plasma cutter and with the Duramax torch you have a winner for sure. Just impossible to get parts for the 1000 if you need but definately run it through it's life, could last a very long time.

I had for a moment considered selling it, it literally has maybe 20 mins total use. I had a buyer lined up for 4k believe it or not. Then I did my research and decided to keep it after realizing the comparable unit, the Hypertherm Powermax 65 SYNC was nearly 8k and all I was really getting was a digital display, consumables SYNC technology and a machine torch with spring start tech. At which point I decided to sell the T60 and upgrade to only the Duramax retrofit torch. I can set the amperage by hand lol.

Not sure the water mist is needed but maybe you have something in mind for it. The downdraft is awesome and I prefer that over a water table with the only downside being heat loss out of your shop on those cold Calgary days.

I fully intend to run both the down draft and water table features. I'm an aluminum fabricator/ TIG welder so its of utmost importance for me to be able to cut aluminum, generally 10ga, but also 3/16", 1/4" as clean as possible, with the least dross, not only accurately for repeatable manufacturing purposes but for ready to weld purposes. So i'll start with the above stated and nitrogen primary. For the real fancy stuff I may add the WMT set up. When cutting aluminum, a combination of nitrogen as the primary plasma gas and water as the shield gas is often recommended, especially for thicker aluminum. This combination can provide excellent cut quality and smooth surface finish, as well as good cut speeds and lower operating costs.

Anyway, curious to hear how the machine is working for you right now.

To be announced in the next several weeks.

What front end software have you used, have experience with and like the most?. I'm leaning towards Sheet Cam. If at some pint I need stronger automatic nesting capabilities and remnant tracking i'll break out the wallet for Flash Cut.

[PurposeBuilt]

It looks like you are on the right track! Please keep us posted as you progress.
David

I certainly will David!

[SegoMan DeSigns]

What I see and have time to respond to now:

1- What ver of software on Masso?

2- What brand of THC?

3- Masso puts out S & D signals to tie into your drivers (or clearpath servos like I use)

4- For signal cable I use Cat 7 shielded LAN cables and plug them into jacks for ease of change out

5- I have an older Hypertherm 1250 that is still in use and gets used for the shop torch, the 65 & 105 are mtd to plasma tables. The older units are great machines, the new SYNC system sucks! (a lot of $$ on consumables)

6- Labeled connectors can be done with colored marking tape or a brother label maker (I won't mention some of us has a vinyl cutter for such tasks

7- There is wireless remote controls that work with a Masso it's documented on their forum

8- I see a CPC interface connector in the photos, if new is needed search the forum for parts nos that can be had for $20 or buy a new cable for $150

9- If you find a one source outlet it will cost you $$ start searching and bookmark your finds (I'm a fan of Ebay & Amazon)

10- Ask away with any questions

[PurposeBuilt]

What I see and have time to respond to now:

1- What ver of software on Masso?
When and if I go this route I'd hope for the newest version of Masso's software.
2- What brand of THC?
Honestly I hadn't thought much outside of using Masso's THC.

3- Masso puts out S & D signals to tie into your drivers (or clearpath servos like I use)
Please elaborate.

4- For signal cable I use Cat 7 shielded LAN cables and plug them into jacks for ease of change out.
This is great info, do you have a specific jack you like to use?

5- I have an older Hypertherm 1250 that is still in use and gets used for the shop torch, the 65 & 105 are mtd to plasma tables. The older units are great machines, the new SYNC system sucks! (a lot of $$ on consumables)
I agree with these statements. Going to keep the 1000 G3 and upgrade to the Duramax retrofit torch to have the spring start.

6- Labeled connectors can be done with colored marking tape or a brother label maker (I won't mention some of us has a vinyl cutter for such tasks I'll definitely take your advice here and label everything clearly.

7- There is wireless remote controls that work with a Masso it's documented on their forum.
Yes, you are correct. Masso does support dedicated wireless MPG pendants. These can be as much as 300USD before shipping. Masso has no USB stack for HID input so I believe I'll have to go through a PC-based intermediary and use a jog pendant bridge software for something like an XboX controller.

8- I see a CPC interface connector in the photos, if new is needed search the forum for parts nos that can be had for $20 or buy a new cable for $150

9- If you find a one source outlet it will cost you $$ start searching and bookmark your finds (I'm a fan of Ebay & Amazon)
I'm am also finding this to be true. Amazon for the win so far.

10- Ask away with any questions
Thank you kindly for your time and offering to answer my newbie questions!

[SegoMan DeSigns]

What I see and have time to respond to now:

1- What ver of software on Masso?
When and if I go this route I'd hope for the newest version of Masso's software.
V5.10 has been released and has better restart fearures for plasma

2- What brand of THC?
Honestly I hadn't thought much outside of using Masso's THC.
Masso's DTHC would allow better access to post processors like SheetCam

3- Masso puts out S & D signals to tie into your drivers (or clearpath servos like I use)
Please elaborate.
My ClearPath servos has an onboard driver so wiring is direct from Masso for S&D signals

4- For signal cable I use Cat 7 shielded LAN cables and plug them into jacks for ease of change out.
This is great info, do you have a specific jack you like to use?
Modular wall jacks like the Keystone brand is configurable in many options

5- I have an older Hypertherm 1250 that is still in use and gets used for the shop torch, the 65 & 105 are mtd to plasma tables. The older units are great machines, the new SYNC system sucks! (a lot of $$ on consumables)
I agree with these statements. Going to keep the 1000 G3 and upgrade to the Duramax retrofit torch to have the spring start.


6- Labeled connectors can be done with colored marking tape or a brother label maker (I won't mention some of us has a vinyl cutter for such tasks I'll definitely take your advice here and label everything clearly.


7- There is wireless remote controls that work with a Masso it's documented on their forum.
Yes, you are correct. Masso does support dedicated wireless MPG pendants. These can be as much as 300USD before shipping. Masso has no USB stack for HID input so I believe I'll have to go through a PC-based intermediary and use a jog pendant bridge software for something like an XboX controller.
What are your tariffs in Canada like?

8- I see a CPC interface connector in the photos, if new is needed search the forum for parts nos that can be had for $20 or buy a new cable for $150

9- If you find a one source outlet it will cost you $$ start searching and bookmark your finds (I'm a fan of Ebay & Amazon)
I'm am also finding this to be true. Amazon for the win so far.


10- Ask away with any questions
Thank you kindly for your time and offering to answer my newbie questions!

Pics of my Cat 7 cabling upgrade. I used a combo of keystone style & patch bay panel, this system allows for a quick replacement of a gantry wire. search Y/T for how to vids on networking connectors they are relative cheap and easy to use with a punch down tool.

[SegoMan DeSigns]

Here is a video of my Machine:

[weldguy]

What front end software have you used, have experience with and like the most?. I'm leaning towards Sheet Cam. If at some pint I need stronger automatic nesting capabilities and remnant tracking i'll break out the wallet for Flash Cut.

I am onto Fusion 360 now, it serves all my needs from cnc plasma to to my cnc mill and lathe. The only time I stray away from that is if I am looking to design something artisitc, I will draw it in Corel then send the dxf to Fusion for post processing. I will follow this topic to see your progress, very interesting project.

Of course SegoMan has the baddest looking wiring on the planet! Wow, that some great cable managment!