Transforming a Rat Rod Project with the ARCCAPTAIN CUT50 Plasma Cutter

Building a custom rat rod is all about creativity, precision, and the right tools. In this project update, the builder takes on a new phase — modifying the chassis for side-exit exhausts and strengthening the frame — all while testing the brand-new ARCCAPTAIN CUT50 Plasma Cutter.

From unboxing to real-world cutting, this post covers how the Cut 50 helped tackle critical fabrication tasks, from cutting oval openings in a car frame to trimming thick steel for suspension mounts.

Project Goals and Scope

This is part of an ongoing rat rod build series, and the main objectives of this stage were:

• Fabricating side-exit exhaust openings in the chassis

• Installing wishbone mounts for the suspension

• Strengthening the frame with custom steel plates

• Testing the ARC CAPTAIN Cut 50 Plasma Cutter on various metal thicknesses

Step 1 – Planning and Preparing the Exhaust Cutouts

The goal was to route the exhaust through the side of the frame, connected to an X-pipe and mufflers.
Key preparation steps included:

• Using 4-inch inner diameter steel tubing for the chassis opening to accommodate 3-inch stainless steel exhaust pipes.

• Creating an oval template for a 60° angled cut in the frame.

• Marking the exact location on the chassis, ensuring clearance from other components.

• Clamping angle iron to the frame to prevent warping during cutting.

Step 2 – Cutting and Finishing the Openings

With the ARCCAPTAIN CUT50 Plasma Cutter:

• Cutting the oval holes in the chassis was quick and precise.

• After cutting, an angle grinder was used to smooth the edges.

• Test fitting the exhaust pipes ensured the angle and clearance were correct.

Step 3 – Strengthening the Frame

To reinforce the chassis around the new openings:

• 1/4-inch steel plates were cut for reinforcement.

• Some plates were pre-cut on a CNC plasma table but required final cutting with the Cut 50 to fit perfectly (ARCCAPTAIN CUT50 is not compatible with CNC).

• The plates were welded to the frame to secure the exhaust and maintain structural integrity.

Step 4 – Fabricating and Aligning the Exhaust Pipes

The exhaust pipes were:

• Cut to match the 60° chassis exit angle.

• Tack-welded in place after alignment.

• The same process was repeated for the opposite side of the frame.

Step 5 – Installing Wishbone Mounts

Another major task was preparing and installing wishbone suspension mounts:

• TIG welding was used to attach the mounts.

• The Cut 50 plasma cutter handled the final cuts on 1/4-inch steel plates that the CNC table couldn’t fully cut through (ARCCAPTAIN CUT50 is not compatible with CNC).

Step 6 – ARCCAPTAIN CUT50 Plasma Cutter Review

This build also served as a real-world test of the ARCCAPTAIN CUT50, highlighting:

Key Features

• Compact and Portable – Lightweight with a shoulder strap and handle.

• Dual Voltage (110V/220V) – Automatic voltage detection.

• Included Accessories – Torch, consumables, ground clamp, air hose, and shoulder strap.

• 2T/4T Mode – Allows for continuous cutting without holding the trigger.

Cutting Performance

• At 110V, delivers up to 35 amps, easily cutting 1/4-inch steel.

• Tested on 1/4-inch, 1/2-inch, and 3/4-inch steel plates.

• Clean, smooth cuts on 1/8-inch steel with minimal cleanup required.

Step 7 – Upcoming Work

While the exhaust and reinforcement plates are tack-welded for now, final welding and finishing will be completed later in the build. Additional bodywork, such as fairing modeling and installation, is also planned.

Why the ARCCAPTAIN CUT50 Was the Right Tool for This Build

The plasma cutter proved invaluable for:

• Precise chassis modifications

• Cutting thick steel for structural reinforcement

• Speeding up fabrication without sacrificing accuracy

Its portability, dual voltage capability, and clean cut quality make it an excellent choice for garage builders and professional fabricators alike.