On Wed, 03 Jun 2009 20:02:31 -0500, RoyJ
wrote:

we just acquired a PILE of 1" to 3" aluminum plate drops from a local
manufacturer. What we really need is a selection of project pieces in
the 1"x 1" to 3" x 3" range. No particular sizes, just stuff than can
stay on the shelf, get cut to length and tossed in the mill as required.

Thought was to rip them using a Skill 77 worm drive. Anyone got some
recommendations for the perfect blade or other thoughts on how to get
them cut down?

I have a Freud non-ferrous blade for my table saw that works well and
gives a nice finish if you apply a bit of stick wax between cuts.
There's a Freud 7-1/4" non-ferrous blade with a diamond arbor for your
worm drive at the top of this page.
http://www.toolmarts.com/nonferrous.html

The downside to the triple-chip grind, which all the non-ferrous
blades seem to use, is that they seem to push the work around more
than other grinds, which I think might make it difficult to steer a
skil saw. When running the non-ferrous blade I use a sliding board on
my table saw, or clamp the work securely in a chop saw, if I'm
concerned at all about accuracy.

--
Ned Simmons