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Hello Geof,

wow, what a great plan and thank you for the illustration -- very well done! I will try your design as well. I have the following questions:

(1) I imagine the stop pin hole is...

Thank you for all your ideas and replies. For now, I will try the suggestions that will allow me to use the equipment I already have (10" Miter Saw with the Freud Diablo 10" Non-Ferrous Blade).
...

Hello MC-motorsports,

Thanks for your reply. let me know (or anyone else) about the following setup for my AL needs:

Chop saw:...

martin,

HAH :D ... Well, I can ask the old couple across the street ... But i think her husband is an ex WW2 war hero ... not worth the risk. I may have to go to Wal-mart and use the...

Hello Geof,

I already have the following Non-Ferrous blade ( Amazon.com: Freud D1080N Diablo 10-Inch 80 Tooth TCG Non-Ferrous Metal and Plastic Cutting Saw Blade with 5/8-Inch Arbor and...

OK, so I will be getting a metal bandsaw, tomorrow. I have the following questions:

(1) For the foreseeable future, I will just be cutting aluminum square rod (1" to 3" square) with a 1/8" wall...

UPDATE!!! I was out of town this weekend so I finally tried one solution, today. I connected the router speed control to my Miter saw and lowered the speed of the saw to the lowest level. The saw...

Thanks for the additional ideas, ProFab. I called HofT and they have the Pioneer Speed Control for a mere $28.08 (http://www.houseoftools.com/product.htm?pid=15530). It's a great deal but, because...

Thank you Motor-sports, I will definitely get the metal bandsaw from HF and report back with the results. I have a few more questions:

(1) HF is notorious for not including detailed instructions....

Thank you for all your replies. They have all been very helpful. I hope you can answer the follow-up questions / comments:

* I have thought of asking a machine shop / local metal place to do my...

Hello rosko,

Thanks for the reply. Unfortunately, clamps will be very difficult if not impossible. The "slices" I will cut will be as thin as 1/2" ... I hope to cut both square and round...

I am a hobbyist and would like to cut, for example, aluminum square tubing (Any size from 1", 1.5", 2", 3" square and 1/8" thickness/wall) into many "slices" of varying sizes (like a loaf of bread). ...