The only solution I see is to get an
appropriate blade. I bet your 28 tpi blade is fine for cutting 1/4"
ply, but for anything thicker than that, call Iturra designs
(866-883-8064) and get a real blade.

Sorry - must have missed the fact that you're cutting aluminum. My
above response applies to cutting WOOD with a bandsaw - for some
reason, I just assumed that's what you were talking about on this
newsgroup.
Andy