DIY Plasma Tube Notcher

Last modified: July 16, 2024

Imagine you were tasked with constructing a series of space frame tube chassis similar to this one:

Vibrant green metal frame with complex tubing on sawhorses in a workshop setting.

Making a bunch of space frames means notching a lot of tubes...

Making all those space frames means notching a lot of tubing.  Sounds like a little CNC-style automation is in order.  That resulted in this CNC-driven plasma cutter tube notcher that I came across over on Reddit:

Well-lit workshop with various machinery and equipment, featuring a large metal frame on a stand.

Start by welding up a simple frame.  The plasma torch will ride along that rail...

Metal part with bolt and chain.

A simple chain drive pulls the torch sled up and down the rail...

Steel object with two bolts and nuts on a gray concrete floor.

The sled itself is very simple and rides on ball bearings that engage the rail corners...

Dark gray metal chain with rusted links attached to bolts on a black metal frame in a cluttered workshop.

Another view of the sled showing the attachment to the chain...

Metal framework with multiple chains on a concrete floor.

A pivoting bar will hold the torch.  It rides on the tubing (bottom) to be cut so torch height can be set...

Metalworking machinery parts with various components and tools.

Torch is held to the bar with brackets...

Metal rod with yellow and silver wheel attached.

The tubing sits on skate wheels (so it can rotate) on a parallel frame...

Rusty wheel hub assembly with nut, washer, and chain, on a workbench or floor.

A Chevy Cobalt wheel hub is the perfect base for the 4th axis...

Heavy-duty lathe chuck with four-jaw self-centering design and adjustable tailstock.

Add a 3-jaw chuck from a weld positioner to hold the tubing...

Black metal chain drive mechanism with sprocket and cable attachment.

Stepper motor for the chain axis is also chain driven...

Black metal chain wrapped around a gray gear on a metal frame with a silver rod.

With another chain-driven stepper motor for the rotary axis...

Blue and yellow machine with control panel and tools in a workshop setting.

Throw on a little paint to make it pretty and you've got a CNC plasma tube notcher!

Mach3 is perfect to drive it.  The architecture is just 2 axes, but one is rotary so a lot can be done.  The tubing notches come out great.

Be sure to check out the DF Kit Car site that's what all this is for:

DF Goblin CNC machine in a machining or metal fabrication setting.

I bet these little Goblins are a real handful but a total blast to drive!

Be the first to know about updates at CNC Cookbook

Join our newsletter to get updates on what's next at CNC Cookbook.