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Update May 28
Get the aluminum pieces cut.
Verify that the cutoff saw still cuts plumb and square. A shim was adjusted, and it's good to less than 1/16 of an inch across a but of 2 inches. That's the smallest I can measure. HOWEVER, going by the amount of light that shows between the square and the cut edge, it's a lot better than 1/16. Perhaps less than 1/32.
So the saw is good. Now to cut the piece. Yesterday's 'optimizing' gave the following cut pattern:
40, 0.25 for the blade, 39.5, 0.25, 22.5, 0.25 and I have a piece of scrap - 17.25
40, 0.25, 39.5, 0.25, 22.5, 0.25 and I have a piece of scrap - 17.25
40, 0.25, 42.5, 0.25, 22.5, 0.25 and I have a piece of scrap - 14.25
40, 0.25, 42.5, 0.25, 22.5, 0.25 and I have a piece of scrap - 14.25
Cutting of the aluminum went well:
- measure and mark 10 foot long tube
- align on saw
- fine adjustment for piece on saw base to get length correct
- clamp in place
- pour water on piece
- cut through top and sides
- pour more water - it steams and cools the piece
- cut through the bottom
- support cut end when the cut goes through
Actual sizes varied by a small amount. I cut the 39.5 long, more like 39.625
Attached pictures - bench with chop saw (sorry about the fuzzy, out-of-focus picture), cut aluminum pile
Aluminum needs edges filed, rounded to get rid of sharp, dangerous edges.
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