Posts: 22,684
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Joined: Feb 2005
Location: Regina Saskatchewan Canada
I would bet good money that the piece you saw go flying was not properly supported by the saws fence or was being handheld while cut with some type of circ saw. In that respect, aluminum is no more dangerous than wood. Cut quality is the same thing, proper tooth count and feed rate makes a big difference. Just curious what Dremel bit or cutter you think will make a better cut than a good table or miter saw blade? If you want perfect mitres, be prepared to dress them up a bit with a flat file. It's pretty easy.
Blackhat
Bad experiences come from poor decisions. So do good stories.
Posts: 923
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Joined: Nov 1999
Location: Williston ND
I will bet dollars to dougnuts I can cut the track in 1/10 the time using my table saw and miter sled and a regular combination carbide blade. I have cut hundreds of pieces of aluminum and brass on a tables saw and never once had a piece get thrown anywhere.
I will bet more dollars to doughnuts my cut will be smoother and straighter than can be accomplished using a dremel.
That being said, cut it any way you want, your way might not look as pretty as mine but it should work just as well.
But, if you already have your mind made up, why you asking? Just go do it.
Proud maker of large quantities of sawdust......oh, and the occasional project!