Making a "Small" cut with a zip wheel

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I had to remove part of the eve to make room for a new bulkhead 12' long and overhead   Because the metal is only .25" thick. They had me cut it w a zip wheel.   Torch may have caused warpage and my partner had the plasma cutter.  I got stuck w a grinder and a 3/64 zip wheel.I'm a grinding expert. Not a zip wheel expert.  I was a lil nervous when the foreman said NO MISTAKES!    This is the finish cut no grinding.    Cutting w a zip wheel for me its hard to make a straight cut.  To make it easier we snapped a line. Center punched the line every couple of inches. Then zipcut a groove on the snapline.    After that I made 12-15 inch cuts till I was done.  I'm pretty happy w the results.  I recommend a respirator goggles and welding hood when working overhead.   I had my grinder inverted so I could see better.The foreman said I now have a Phd on zip cutting. Lol.Last edited by galencwi; 10-08-2011 at 03:34 PM.“I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair
Reply:Grats! I use a zip wheel for cutting alot! It's more precise and finish product is ready for the next step.Semper FiJesus may have been a Carpenter, but his dad was a Millwright" A grinder and a can of paint, will make a welder what he aint' "I've done so much, with so little, for so long, that now I can do anything with nothing!
Reply:Heres the pics Attached Images“I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair
Reply:why no grinding?Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:They wanted a Sharp straight edge. The plans call for something to fit up to it.   Hey whatever's quicker.  This boat has a lot of hazadous paints/ materials like lead zinc and asbestos.   I'd rather grind as lil as possible.  Everything gets checked before we touch it.  But I'm all about making as small of mess as possible.“I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair
Reply:It looks pretty accessible, why not just clamp a guide on it?Buy American, or don't whine when you end up on the bread line.
Reply:First off I couldn't see anything of value in the pictures.  and second I dont have a clue what a zip wheel is.  Enlighten me please.  Mac
Reply:A zip wheel is the thin abrasive wheel for cutting slots.  It's similar to the 14" abrasive chop saws, but the disk is usually only 3" or 4" diameter.  Works well on electric grinders or air die grinders.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Originally Posted by WeldingMachineIt looks pretty accessible, why not just clamp a guide on it?
Reply:Originally Posted by galencwiI tried using a guide today.  The zipwheel cut into it.
Reply:I've got a guard that fits on my 4 1/2" grinder similar to whats on a circular saw. We would lay out a straight edge and run the foot of the guard along it just like you would with a straight edge and a circular saw. We used it for grinding "grout" lines in decorative concrete for doing pattern work. With a tall straight edge like a 2x4 you can slowly keep making progressively deeper cuts if needed simply by "carrying" the grinder over the cut. The big difference with the zip wheels over the diamond wheels we used is that the zip wheels wear down and you have to keep constantly adjusting the depth if you don't carry the grinder and keep the wheel in contact with the metal. I've used it a couple times to cut expanded metal and sheet material before I got my plasma. Attached Images.No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by WeldingMachineQuick tip with using a zipwheel with a guide:  Score the whole cut & work the cut in multiple passes.  Don't cut all the way through the stock before having the score line well established. (Or you will cut into the guide).  I hope it helps in the future.
Reply:Originally Posted by WeldingMachineQuick tip with using a zipwheel with a guide:  Score the whole cut & work the cut in multiple passes.  Don't cut all the way through the stock before having the score line well established. (Or you will cut into the guide).  I hope it helps in the future.
Reply:Those long angled cut off wheels that SnapOn and MAC sell are awesome for making nice straight cuts, another thing is make sure that the spindle spins nice and true and you will get a nice clean straight cut, also this might sound stupid but save some the discs that are all most used up and you can use them to get into tighter spots..... Attached ImagesLincoln pro mig 180Lincoln Square Wave Tig 300/wp 20/home built water cooler Victor, Purox, Harris, O/A welding/cutting setupsVintage Craftsman drill pressVintage Craftsman/Atlas 12"x 36'' lathe7''x 12'' w/c band saw Everlast 140 st
Reply:So Zip wheel is a 4.5 inch cutoff wheel. I buy them a hundred at a time. theres quite a break on price and they last pretty well.  There great for dismantleing things.  Thanks Mac
Reply:??????????why hav i always called them muffler cutters?????????  lol        thermal arc 252i  -  millermatic 350P -   miller XMT, cp300ts, 30a 22a feeders, buttload of other millers, handfull of lincolns, couple of esabs  -   Hypertherm 1250 G3
Reply:Thats funny woi2ld.   I have never seen or used one until this year.  Im sure they have been around forever.  Wish I had zipwheels when I started hauling scrap a long time ago.“I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair