I'd have thought even "square to a set square" would be tricky without a lathe.
Depends somewhat on what you want the for, what the finish has to be, and how many you have to make.
It seems to me than that on the very specific issue of cutting this aluminium bar I have, both a circular saw as well as a grinding disk are non starters, because the bar needs a slow-moving blade action. Looks like I'll be hand cutting this bar. Unless I am willing to buy some powered hacksaw I can afford. Which seems a bit over the top if I'm not cutting aluminium bar of this size regularly.
If the table in front of my rotating sand disc is square with the disc, and if the bar is at right angles horizontally to the disc, I'll have a square faced edge on my bar. Won't I? Certainly in theory.
If you rotate the aluminium bar as you are facing it on the disc sander, you'll get a reasonably accurate 90 deg finish - with the emphasis being on 'reasonably'.
Is that good enough for your project?
John
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