I have circular saw made for metal cutting and a blade designed for aluminum, it was not cheap but it leaves my band saw in its dust. The blade runs at a slower speed than your normal chop saw and is designed for low heat, you can pick the piece up by hand right after cutting it as long as you follow the prescribed speed of cut. It has saved me an awful lot of work and time, I know this is way to big for your needs Rob I was just putting this out there for anyone who needs to cut aluminum, I cut up to 2 inch round with it. All the best, Neil.
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