How to Use a Plasma Cutter for Auto Sheet Metal

Plasma cutters convert moving air to high-temperature plasma with electrical frequency. This allows a plasma cutter to cut through light gage automotive sheet metal. Using a plasma cutter on a vehicle requires pre-planning as the heat and electricity cutting through the metal can spark a fire or melt electrical wires near the cut. Preparing the vehicle prior to cutting will reduce the chances of a catastrophic accident occurring while cutting automotive sheet metal.

Instructions

1

Open the hood of the vehicle. Remove the ground cable from the battery with an adjustable wrench. Set the battery cable in an area where it will not contact any metal.

2

Place fire blankets over the tire(s) near the cut area. Remove all flammable materials from the area around the vehicle. Place a fire extinguisher near the area where you are working.

3

Sand the paint from the area where you intend to start the cut with 60-grit sandpaper.

4

Hook the ground clamp from a plasma cutter to a metal part on the vehicle. Plug in the plasma cutter.

5

Put on a pair of burning goggles. Set the tip of the plasma torch 1/8 inch off the surface of the auto sheet metal you sanded with sandpaper.

6

Pull the trigger of the plasma gun. Pull the plasma gun along the sheet metal. Slow down your speed if sparks shoot back toward you.

7

Allow the cut piece of metal to cool for 30 minutes after it falls from the vehicle. Do not leave the area while the piece cools to ensure no fires start from stray sparks.