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When I cut aluminum bar or t-slot extrusion on my bandsaw I am not happy with how "square" this edge is. I don't have a milling machine at home, and I have been told grinding aluminum is a very bad idea.

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    $\begingroup$ A file works well... $\endgroup$ – Solar Mike Mar 13 at 20:52
  • $\begingroup$ Good idea - is there a way to make sure that the file is square so that the end of my t-slot bar will be flat? i.e. some sort of jig? $\endgroup$ – user391339 Mar 14 at 0:41
  • $\begingroup$ I have a feeling something called a die filing machine could do it well $\endgroup$ – user391339 Mar 14 at 2:07
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    $\begingroup$ My sons had 3 weeks of practice manual filing before touching any macine... and it had to fit. $\endgroup$ – Solar Mike Mar 14 at 4:01
  • $\begingroup$ Depends how many you need to do. Just find a square corner, and offer it up, looking at the gap, and re file as necessary $\endgroup$ – Jonathan R Swift Mar 14 at 9:43
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I used to build structures using the 80/20 aluminum extrusions , I used a mitre saw with a good aluminum cutting blade lubricated with stick wax (or any good cutting fluid). Makes beautiful square cuts with minimal burring. Be careful applying the stick wax to the rotating blade, otherwise your mitre saw will become a finger removing device by default :-(

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