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post #6 of Old 07-30-2013
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Re: cutting down aluminum masts


Throw it on a chop saw with a carbide blade. I am a skylight designer (not rectangles). We use aluminum extrusions of the same alloy as masts. Many of the fabricating steps involve chop saws and clamps. Be sure to block it up, make it parallel with the fence and the table and be sure the saw is squared up as well. Clamp it in place. Take your time cutting through the material and don't sweat it if you're off 1/8". That's what turnbuckles are for. After cutting, clean it up with emery cloth. The burr will be on the bottom of the material. That means the inside on the top and the outside on the bottom. Most of all, don't freak out. We do this ALL THE TIME. Just be careful. Be sure to wear goggles and no gloves.

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