Cutting the extrusion

So as I purchased my extrusion as 6x1000mm lengths I needed to cut them down. For this I used my chop saw that is capable of cutting aluminium and actually did so rather well (it's something like http://www.evolutionpowertools.com/uk/project/fury3b.php)

There are a couple of issues I needed to overcome.

1. How to ensure the cut is square
2. How to ensure every length is exactly the same size

How to ensure the cut is square

There are few good videos on youtube for how to ensure your fence is square I suggest you follow one of those. In my case I took repeated slices of wood and measured the width of them at both ends - https://www.youtube.com/watch?v=IP6LXisbrIY

How to ensure every length is the exactly the same size

For this I clamped the saw to the workbench and clamped an end stop so each length would be roughly 300mm - it didn't have to be too accurate as long as the length was consistent. The leftover from the cut was to be the vertical leg.