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Thread: Duramax torch retrofit for TD 100xl?

  1. #1
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    Duramax torch retrofit for TD 100xl?

    My well used TD 100xl torch head developed an internal short the other day, the 100xl supply itself seems fully operational and protected itself.

    Are there any modern torch/consumable sets that can be retrofitted? Looking for longer consumable life etc.

    I dont mind spending real $$$ on a brand name torch, but the cost of a new TD direct replacemnt torch is not happening at $900+
    (Even the head alone is almost $500)

    The TD SL60 appears to work for blowback or cd/hf uses, but even its a bit long in the tooth.

    I was wondering if any of the Duramax torches will work for CD/hf pilot arc systems?
    Last edited by waferhead; 4 Weeks Ago at 05:23 PM.
    1999 Synchrowave 250, Bernard cooler.
    TA 181i, US version, with TA 181i Euro connector, Euro on torch.
    Firepower spool gun w/Euro connector, modded to suit 181i
    Pressure controlled TIG amptrols.
    TD PacMaster 100XL plasma cutter

  2. #2
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    Re: Duramax torch retrofit for TD 100xl?

    SL-60 is your best option., really simple with the standard non ATC torch end..Just run the Thermal Dynamics 8-3440 Restrictor Pin with it.. You can use the black electrodes for gain some there. and you do have nozzles in sizes from 20/30/40/50-55/60/70/80/90-100 to chose from, along with 4 gouging types. Shielded cups. It's the cheapest/ best, and proven way to go..

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  3. #3
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    Re: Duramax torch retrofit for TD 100xl?

    Thanks, will look for sl60, and thanks for the link.
    The heads appear to be cheap/common enough, although i need to find a parts breakdown to see how the hose/handle etc connects.

    I'd prefer to keep the existing 25` hose etc as its in perfect shape, seems more expensive than the torch
    time to Google....
    Last edited by waferhead; 4 Weeks Ago at 06:31 PM. Reason: added info
    1999 Synchrowave 250, Bernard cooler.
    TA 181i, US version, with TA 181i Euro connector, Euro on torch.
    Firepower spool gun w/Euro connector, modded to suit 181i
    Pressure controlled TIG amptrols.
    TD PacMaster 100XL plasma cutter

  4. #4
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    Re: Duramax torch retrofit for TD 100xl?

    If you have the pak master 100 XL The ob2 version of the SL60 torch is what you want. you also will need the adapter kit. If you like the atc plug there is also an adapter To add that. Just go to ESABNA and search it out. Look up the SL 60 plasma torch.

  5. #5
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    Re: Duramax torch retrofit for TD 100xl?

    Several popping up out of the woodwork, cheap, new.
    i may try to adapt my existing cable set as an extension, gets me to 45'.
    Can this discussion be moved to another forum? (right forum for question, but the correct answers render it wrong forum)
    1999 Synchrowave 250, Bernard cooler.
    TA 181i, US version, with TA 181i Euro connector, Euro on torch.
    Firepower spool gun w/Euro connector, modded to suit 181i
    Pressure controlled TIG amptrols.
    TD PacMaster 100XL plasma cutter

  6. #6
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    Re: Duramax torch retrofit for TD 100xl?

    This is the adapter. Forget using your old cable.. The other adapter allows you to use ATC style torches and extensions Just give you two torch style machine ends..You will need the 7-3447 no matter what torch end you use..


    VICTOR THERMAL DYNAMICS 7-3447 Torch Adapter Kit,For Thermal XLs

    https://www.airgas.com/medias/CM-000...I4N2EzNzdjYzIy
    Last edited by Brand X; 4 Weeks Ago at 06:28 PM.
    Esab/Lorch ET-220i
    Esab 160i caddy
    Thermal LM-200 Lincoln feeders
    Thermal Pee-Wee 85s
    Thermal 60i- 3phase /RPC powered (Beast)
    Thermal Drag-gun 35C
    INE 1500
    Klutch 140i

  7. #7
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    Re: Duramax torch retrofit for TD 100xl?

    Quote Originally Posted by waferhead View Post
    Thanks, will look for sl60, and thanks for the link.
    The heads appear to be cheap/common enough, although i need to find a parts breakdown to see how the hose/handle etc connects.

    I'd prefer to keep the existing 25` hose etc as its in perfect shape, seems more expensive than the torch
    time to Google....
    I'm pretty sure I have a couple SL60's I could sell. Probably have an adaptor and a ton of consumables as well. I can send a pic or 2 if interested. I'm thinking $150 for the torch alone, 1/2 price consumables. Let me know.
    Thermal Arc 320SP ( Lorch )
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    Victor Gas Apps.
    Boxes and boxes of welding crap.

  8. #8
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    Re: Duramax torch retrofit for TD 100xl?

    Thanks all, scored new, ~cheap, looks like ~direct bolt on replacement, non QD.
    bought it last night or I would have jumped on the $150, may yet to have a spare...

    Will need consumables as I'm starting over.
    Need to get one of those restrictor plugs to neuter the start cart.
    Last edited by waferhead; 4 Weeks Ago at 11:51 AM. Reason: canna spel
    1999 Synchrowave 250, Bernard cooler.
    TA 181i, US version, with TA 181i Euro connector, Euro on torch.
    Firepower spool gun w/Euro connector, modded to suit 181i
    Pressure controlled TIG amptrols.
    TD PacMaster 100XL plasma cutter

  9. #9
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    Re: Duramax torch retrofit for TD 100xl?

    Quote Originally Posted by Rondo View Post
    I'm pretty sure I have a couple SL60's I could sell. Probably have an adaptor and a ton of consumables as well. I can send a pic or 2 if interested. I'm thinking $150 for the torch alone, 1/2 price consumables. Let me know.
    You have a pm.
    1999 Synchrowave 250, Bernard cooler.
    TA 181i, US version, with TA 181i Euro connector, Euro on torch.
    Firepower spool gun w/Euro connector, modded to suit 181i
    Pressure controlled TIG amptrols.
    TD PacMaster 100XL plasma cutter

  10. #10
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    Re: Duramax torch retrofit for TD 100xl?

    Quote Originally Posted by waferhead View Post
    You have a pm.
    I also found a 7-3447 adaptor as well as a whole list of other parts like a pilot arc contactor, 2 torches and a slew of consumables.
    Thermal Arc 320SP ( Lorch )
    Cobra Pythons
    Thermal Arc 300 AC/DC ( Sanrex )
    ESAB 301i AC/DC ( Lorch )
    Thermal Arc 161STL ( WTL )
    Thermal Arc 190S ( Sanrex )
    Cut Master 82, 42. Cut45 ( WTL )
    Victor Gas Apps.
    Boxes and boxes of welding crap.

  11. #11
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    Re: Duramax torch retrofit for TD 100xl?

    Unless there is a way to disable the 2 second preflow, the 100xl simply will not operate sanely with a blowback starter. Works fine with hf start, probably better for my uses. Installed the plug to neuter the start cart, works fine with HF, with some theoretical loss in consumable life due to hf pilot.

    I give up on td consumables, went through ~$100 of them (~$100 is 5 pak of TD electrodes and tips, or 30 each also Made In China shipped 3 day from USA), they work no better nor last a second longer than the Chinese stuff, its all Chinese made anyway these days.
    Last edited by waferhead; 2 Weeks Ago at 03:09 PM.
    1999 Synchrowave 250, Bernard cooler.
    TA 181i, US version, with TA 181i Euro connector, Euro on torch.
    Firepower spool gun w/Euro connector, modded to suit 181i
    Pressure controlled TIG amptrols.
    TD PacMaster 100XL plasma cutter

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