A protective shell for surrounding a portion of a body of a handheld plasma torch includes a first and second shell section. The plasma torch body includes a handle, a head extending from the handle and a torch tip extending from the head. The first shell section is structurally independent from an outer surface of the plasma torch body. The second shell section is structurally independent from the outer surface of the plasma torch body and is capable of being secured to the first shell section such that, in combination, the first and second shell sections surround the torch head and provide (i) structural protection to the torch head and (ii) thermal insulation to the torch head, wherein the first and second shell sections are electrically insulated relative to the torch head.