Any suggestions for Super 160p to get the plasma cutter to work better?

I've got an old Super 160P multi process (tig, plasma, stick) with all the pulsed controls and what not.
I bought this thing back in 2007, and it's been a workhorse in my shop ever since.... But since I got it, I've had this problem... Well annoyance really.
The plasma cutter function leaves something to be desired, and it's often very difficult to start a cutting arc. The HF start function will sit there and fire but no arc will start. Oftentimes to the point where I will just give up and cut it with shears or bandsaw or cutoff wheel.

Do you have any thoughts on a way to make this better? Like I said, it's been doing this ever since I got the machine, and when I do finally get the arc going it cuts just fine.
I always just figured that I shouldn't expect a multi-purpose machine to do everything a well as it's single-purpose counterpart, but if anyone has a suggestion, let me know.

HF gap adjustment is usually the root cause.

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Originally Posted by performance

HF gap adjustment is usually the root cause.

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What would you suggest as the proper gap for the 160? The manual i got with the welder was extremely unhelpful on this sort of thing, and has long since been lost. It was useless, and only had a couple of pages in english, and some very vague and rudimentary drawings as to how to wire the thing. Didn't even describe knob functions or how to setup and use the welder.

The spark gap specs for a similar Super200P machine is according to Mark, supposed to be about .030". Check out this thread:
http://weldingweb.com/showthread.php?t=35536

When you have your machine open, check out if the have the same high voltage capacitor arrangement as mine. Note another HF circuit board, has only one high voltage capacitor, whereas mine has two. Two might work better. It would give a different frequency voltage "ringing" in between the sparks.

Also, good idea to straighten your HF points if they are crooked, and sand off any corrosion with emery cloth, a fishing lure file, or similar.

I've tried as low as .02x" and as high as .060" on mine, but have left it for the most part at .030". I haven't experimented with plasma mode in a while, but never really experienced any major problems with arc starting. At the same time, I have a feeling it doesn't work as easily as a newer machine with pilot arc, which I have not tried.

A couple things that I do remember helped me for plasma cutting:
1. use an inline air desiccant dryer in the air inlet (after the filter/regulator thing, and before the machine)
2. use fresh consumables (make sure the electrode and outer metal consumable piece have the proper gap, and are both in good shape)
3. use a shade 5 or so goggles/helmet (not an arc welding shade 9+... it's too dark to see.)

Spike

How long does it take for you to make a seat?

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Originally Posted by SeanMurphy265

Spike

How long does it take for you to make a seat?

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That is almost entirely dependent on the design and how complex the seat is. Anywhere from a few weeks to a few months of work goes into them. Although, 4-8 weeks is the normal time frame for most projects. Some really complicated seat projects will take longer.