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Hi John, I only use one tip size, a #3, as it will cut 1/16" to 1-1/2" very nicely. Thats a pretty small tip and can be alittle hard to clean, (small orifices) but a good all around size. Pressure is all in how you use your torch. Me I use 40psi/Oxy and 5psi/Acet when I"m away from my cylindersand control final pressure with my torch valves. By that I mean I don"t depress my cutting lever but just a small amount. If I need to blow out some slag in corner then I have the pressure to do so. On the bench, then I use 20psi/Oxy and 5psi/Acet. I very seldom need more pressure than this. I only use a very lite pressure on the cutting lever. If your tip is clean then you will need less pressure. If your tip is dirty then you will need more Oxygen. On a typical cut I just barely have the cut lever depressed. Repost of my torch tip cleaning: A trick I use for accurate free hand cutting is using a sanding disc to knock off the heavy scale and then use a scratch awl for my lines. The line is very thin so it makes following lines very easy. Another is to stop cutting when you feel your hands or torch get out of balance. When that happens, stop and reposition the torch then continue cutting. The cleanest cut comes from a clean tip. After you clean all the orifice bores in the tip, fire up the torch and set flame for cutting, then depress the cutting lever and observe the flame. There should be a long very "uniform" inner flame cutting cone. If that inner cone is not "very" uniform then your cut will be ragged just like the flame cone is and the back of the metal will have slag. Reclean the center orifice until it"s very uniform. A cut with a clean tip will have a very smooth cut surface with very little (if any) slag on the backside of the cut. If either one of these is not present reclean the tip. The center bore orifice can get deformed and the tip needs replaced or cut off. It"s really important to hold the cleaning file straight in the bore hole and just removing enough material to clean the bore to make the tip last a long time. T_Bone
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