So you want to have a plasma cutter cart to put your plasma cutter on? Large industrial-sized CNC plasma cutters controlled with computer numerical control (CNC) are so ubiquitous in industry that many people think that only industries use plasma cutters. But with the latest advances in design and manufacture of plasma cutters, there are a number of handheld and portable plasma cutters available now. These are affordable for the common man, and convenient to use in home-based metal shops and smaller industrial workshops.

Plasma cutters can typically be powered by plugging them into the common wall outlet. Despite its relatively smaller size, especially when compared to industrial size plasma cutters, handheld plasma cutter still weigh around 75 lbs. A rolling plasma cutter cart that can be used to move the machine around in the work area ensures safety as well as convenience for the operator. Here we explain how you can build your own plasma cutter cart.

Things you’ll need:

  • Old push type lawn mower
  • 24″ x 24″ piece of ¾” plywood
  • Short pencil
  • 5/16″ drill bit
  • Electric drill motor
  • Socket set or end wrench set
  • 4 — ¼ x 20 1-1/2 inch long bolts with nuts
  • 4 — ¼ x 20 1-¼ inch long bolts with nuts
  • 16 — ¼ inch washers

Plasma Cutter Cart Building Instructions

  1. You need a lawn mower’s base to serve as an excellent plasma cutter cart. Get one old push type lawn mower either from your neighbor or the local fix-it shop. As long as the wheels are in good condition, it can be used. But if the wheels are old and worn out, they need to be replaced.
  2. Remove the blade and engine from the base. If you can re-cycle them, well and good – they can also be used as parts for some other components of the cart.
  3. Lay a piece of plywood over the top of the base. A 24-inch by 24-inch piece with a thickness of ¾ inch should work fine. Mark the old engine mounting holes using a short pencil.
  4. Drill a hole at each location by using the 5/16 drill bit in the electric drill. Clear the wood from the holes to make sure that the bolts can slide without trouble.
  5. Attach the plywood to the mower base with the ¼ x 20 inch by 1 and ¼ inch long bolts. Ensure that you have used the ¼ inch washer on both sides. Use a wrench to tighten them all. This makes a sturdy base on top of which you will set the plasma cutting machine.
  6. Using the pencil, mark holes for plasma cutter mount points onto the plywood. These include four mounting positions for the lower frame of the plasma cutter. You should orient the plasma cutting unit as you want it on the cart, keeping in mind ease of access.
  7. Drill these marked holes through the plywood and the top of the lawn mower base.
  8. Use the ¼ x 20 by 1 and 1/2 inch long bolts to attach the plasma cutter to the base. Ensure that you have used washers on both sides and tightened the nuts.

Plasma Cutting Cart Tips & Warnings

  • If you want more storage space, you can use a larger base from a larger lawn mower. Make sure that you use a strong enough lawn mower base in every case.
  • More than just a plasma cutter cart, this is a generic cart that can be used for any mounted tool or piece of equipment.