On Sat, 16 Jan 2016 20:28:11 -0500, wrote:

On Sat, 16 Jan 2016 17:07:12 -0800 (PST), "
wrote:

On Saturday, January 16, 2016 at 2:22:00 PM UTC-5, Clare wrote:

A "cold cut" saw would work - it turns a bit slower than the average
table saw, and the blade is made for cutting metal - but I don't have
one and the quality of the finish of the cut would likely leave
something to be desired.

You have a solution with your friend doing it. But do not knock using a table saw with carbide tipped teeth for cutting aluminium until you have tried it. It is noisy, but quick. And the finish is not bad. Try searching on " cutting aluminium table saw ". You will get a couple of pages of links to that topic.

Dan
I've done it several times. I had a 10 inch "Beaver" table saw and
used it to cut 2 inch blocks of aluminum for the engine mounts.(sold
the table saw almost 10 years ago - did I mention we are 16 years into
this build???) The whole garage was full of sharp shiny chips of
aluminum.

I also cut some 3/16" aluminum plate for an engine cover - and that
cost me over $100 for a new armature for my favorite circular saw -and
spread chips all over the back yard. THAT cut was extremely noizy-.

The cuts were smoother than chopping with an axe, but would require a
lot of sanding or grinding to make the surface quality I want for
these parts - which would make any kind of accuracy very difficult.
Not that it is particularly relevant in this application, my favorite
tool for cutting aluminium is my cheap ass band saw ("Simple Simon"
brand from Wilson Brass and Aluminium Foundry in Toronto) with a 4TPI
wood blade. This saw doesn't even come with a rip fence but
modifications have been made.
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Gerry :-)}
London,Canada