After battling silicone and RTV but still leaking I decided to weld the top and bottom of the pan. I ground out the nut and bolt slots on the top to get and better weld. Came out good. No leaks now.
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Looks good, are those burn marks in the bottom of the pan?
Yeah those are burn marks from the torch. They happened when I first started cutting on it. I’m not sure what I did wrong to cause them.
How much water was in the pan? What amperage were you cutting at?
At 45A with a RW45, and a “full” pan, we’ve yet to get any marks on the pan.
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I don’t remember who much water was in the pan at the time, probably not enough. I have a Hypertherm 45xp and it would have been set at 45 amps. The marks on the bottom of the pan are the only ones on the bottom but there are marks all over the top of the pan as you can see in the pictures
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Looks good till you cut through the flange on accident… 
Why would it cut through the flange? Has not
Cut through it yet
Maybe because it’s higher than the bottom on the table? I haven’t heard of anyone who has welded it, cutting through their welds. If I was worried about it I’d slap a piece of angle bar over it.
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I TIG fusion (no filler rod) welded mine, top side only, quite a while back and have not burned through. I guess if your water level was low enough maybe but seems like a long shot.
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