Cutting Channels

I recommend you get one with adjustable blade tension and a front + rear grip to make life easy. Tighten the saw blade so it’s as stiff as you can safely get it. Clamp your channel tight to a surface and put your cut as close to the clamp as possible. The less flex and wobble, the better it will cut.

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I could not get my old hacksaw (that probably has the wrong blade type) to ever bite into a SS channel. Ended up buying a couple 18" aluminum channels to cut up when needed.

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I just cut some with my baby hacksaw. My guns were on fire when I was done. :muscle:

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If you really need a plethora of sizes, why not just buy a bunch of 24" channels and cut them down to size one saturday? Channels are relatively cheap, cut them in 1" sizes and be done. The only thing I hacksaw on site are screen frames and that’s soft enough that I could use a Ginsu knife if I really wanted.

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Hit it with the GINSU CHOP! HIIIYAA

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I use Dremel tool like @Cinder does, 1st 1 inch cut off tool, then sanding wheel, then I used tiny sanding tool (one on Dremel) to get inside of channel:

all tools:

always using some king of protective glasses!

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Hacksaw and then grinder then a fine file, wish I had a dremel, would be easier!

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https://m.harborfreight.com/power-tools/cut-off-saws/6-in-55-amp-cut-off-saw-61659.html

This little baby. Great for square or miter cuts on screen frame too.

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Yeah but this one is awfully cute. And perfect for screen frames.

https://m.harborfreight.com/power-tools/cut-off-saws/2-in-mini-bench-top-cut-off-saw-62136.html

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I was gonna buy that mini cutoff tool for cutting arrows.

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wanna go do karate in the garage?