[Ken Orme]

I use a vertical band saw with a metal cutting blade on it. The metal cutting blade is tempered and has fine teeht. I cut alum, brass and copper. I found out the hard way not to try to cut steel with it, sparks will fly. I have cut square aluminun tube to make a special size channel. I either use a belt sander then files on a piece 2 feet or longer.

The trick is to use a metal cutting blade or a very fine tooth blade