The dude butchered my aluminum extrusion :( !!!

[John McNamara]

Some extrusions have a central hole, if yours has one you can turn the ends between centers if you have access to a big enough lathe. obviously there will be a small pip left, that can be removed with a countersink or filed off.
This method will produce close to perfect 90deg end faces.

Being Aluminium I don't think a half centre would work well.

[magicniner]

If you had a square and a scriber you could mark it out accurately and cut it with a hacksaw then finish with a file.
Everyone seems to forget completely about the importance of good bench work once they've seen a machine ;-)

[Ger21]

A sliding table saw with a very sharp blade will also work.

[cropwell]

Everyone seems to forget completely about the importance of good bench work once they've seen a machine ;-)

I have a piece of my late father-in-laws work from his pre-war Army training in the Signals. It is a test piece, a steel plate with a 1" square hole and in the hole is a friction fit 1" steel square. You can put that inner square into the hole in any rotation or turn and the fit is the same - perfect. All this was done with a drill, a file and a micrometer. My bench work is crude and impatient by comparison.

[Boyan Silyavski]

The way to do it is go to butchers with a small precision square in the pocket. And politely check their machine before cutting. Once they see the precision square, they will understand you mean it square... I have been laughed at but at the end i achieved mine, in terms of precision...

Better to know you as the Precision Loco. In Spain we say : El que no llora no mama, meaning if you don't cry there is no a tit for you

[Clive S]

Or you could say: yo solo habla catato

[Fancy]

I read your comments and I've decided to go to a machine shop with a mill to trim the ends. Hoping to get away with trimming 2mm total. Also I am gonna keep you posted on my build log. Thanks for the help guys.