How to Gouge With a Plasma Cutter – Kevin Caron

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#esabweldingcutting #cuttingbeast #PlasmaCutters #PlasmaCutting #ESAB #ThermalDynamics #KevinCaronArt From –

Artist Kevin Caron is about to do some metal gouging.

Why would you want to gouge something? With metal, it might be to take a weld off of two pieces of metal such as when you want to remove a weld from the bottom of an angle bracket. You can just gouge that weld out. If you have a piece of metal that’s welded together in a butt weld, you can also gouge that weld out. It’s just removing a weld or removing steel.

To show how to gouge with a plasma cutter, Kevin Caron is going to use the ESAB Cutmaster 60i “beast” of a plasma cutter. He’s going to cut a channel in a piece of 5/8” steel that he had marked out. He is going to gouge it out halfway, then poke a hole through one end as if he were going to lay a wire or cable in it.

Before Kevin Caron can do that, though, he has to change the tip and cap. He unscrews the cap that’s on the Cutmaster 60i, removes the cutting nozzle, pulls off a ring and pulls out the electrode. It’s a nice new electrode, so it’ll still work for gouging – there’s no difference in them. He puts the electrode back in and its cap over it.

Next, Kevin Caron puts on a gouging nozzle, which has a bigger orifice in the end of tip than the standard nozzle. Then he puts on the gouging cap, which is obviously different than the standard cap he had been using. Last he adds an additional ring that screws in on top of the cap. That recesses the tip down inside the cap.

Kevin Caron sets the plasma cutter at 40 amps so doesn’t have quite as much heat coming off the end of it – he doesn’t want to blast all the way through just yet. He has his safety glasses and other welding safety equipment and has set up a backstop for all the sparks are going to be created. Then he warns viewers: “Remember, I’ve never done this before. So you’re learning with me.”

Kevin Caron gouges the 5/8″ steel easily. “That’s not bad for a first timer,” he says, “but I think I can do better. Let’s take another whack at it.” He goes through the channel again, weaving slightly. The channel looks cleaner, but, he says, “Practice does make better or perfect.” He likes the look and thinks about using the tip to actually sculpt something.

Now he has his channel gouged out, it’s time to cut the hole that a wire might feed through. Kevin Caron uses the ESAB plasma cutter to cut a nice square hole in the end. “That’s for all of us round pegs in the world,” he says.

Kevin Caron is impressed with the machine. But all this talk of gouging has made him think of gorging, and now he’s hungry and ready for lunch. He reminds viewers to subscribe to see more free how-to videos, and this is a good time to learn more about this “beast” of a plasma cutter by going to . Well, you might want to stick around for another moment and see him face the harsh realities of creating videos ….

“Inspired sculpture for public & private places.”

Artist Kevin Caron has been sculpting full time since 2006. See – and hear – his amazing metal and large format 3D-printed sculptures, which are found in public and private places coast-to-coast and online at

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John Grady says:

I am a farmer and now I am going to switch one hay fork to another tractor. I have to remove some previous welds. Torch it, cutoff wheel, metal hand held saw or gouge it with my plasma cutter? Recommendations?

Johnny Gregory says:

Nice job, Kevin. Bob Moffatt over on's channel also discovered plasma gouging and demo'd the Cutmaster 60i's doing it. Video is calledGlad you real pros are guiding the rest of us to new and easier techniques of working metals. Thanks, brother.

Blood Sweat And Tears Forever learning says:

Kevin, can you help me understand how a "40" amp plasma cutter works on a 15 amp circuit breaker , my welder does the same thing I can't figure it out

Ken Goudreau says:

Try pushing while gouging works a lot better Kevin..

oliver reid says:

love ur videos kevin!

Mel Gross says:

Sometimes the pilot arc is on and the plasma arc doesn’t start. I don’t always notice right away depending on the angle of the torch, and I gauge when I don’t mean to. I have to say though, the pilot arc makes a very clean shallow narrow (3/32”) gauge. If it didn’t damage the machine, I would figure out a way to turn the plasma arc off and just use the pilot sometimes. I can get very neat lettering that way, but the plasma comes on, and so it’s not practical. I’m using the new ?Thermal Dynamics Cutmaster 40.

Ernest Murphy says:

Kevin I have a cutmaster 51 but it is a Thermal Dynamics not ESAB

Kojo Mensah says:

Kevin you have a lot of content there is so much on YouTube I know that you consider yrself to be just an artist but what about you going into designing stair case or you don't want to be involved in that, with yr artistic mind I could see you doing well in that??

Kojo Mensah says:

You could put all yr vedios on DVDs and sell them at affordable price

Mr Wolf says:

Have you seen gouge nozzles for alphacut 60 or ipt-60 torch? Maybe I have to drill out a oval nozzle?


Hear form 20/20 The Real Rookies

Dieselfumes1982 says:

Kevin!!!! your on TV right now on the 20/20 glad u made it.

Mountain Man says:

Hey Kevin I'm watching you on ABC right now!! Great art work!!!

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