We do not have an XL version of this kit.

Unfortunately we don't test with other brands to confirm compatibility. What we can say is that we know these fit CB-50 torches.

This kit comes with the 1.mm nozzle (like what arrives with the machine). If you want the .8mm - you will need to purchase them separately.

That is a very difficult question to answer, as there are so many variables. It depends on the thickness of the metal and the air pressure that you're using. To make the consumables last as long as possible we would recommend following this air pressure and Amp chart. If gives the psi and amps for the thickness of the metal that your cutting. Also, a good tip when you're cutting your thicker metal would be to look down through the cut, as your cutting if you see the molten metal melting back on itself, that means your cutting a little to slow. Move fast enough to cut all the way through. https://www.eastwood.com/images/email_images/brand/cms_content/tech_article_content/Plasma40Chart.pdf

The plasma would cut fine through heavy rust, the only issue you may run into is you will have to have a clean spot to have the ground on.

A very quick way would be to look at the amperage knob as see what the max it turns too. If it says 40 at the highest you know you have a Versa cut 40.

This nozzle is 24mm OD.

We recommend contacting our Customer service department for help getting your new plasma cutter set up and running.