Until I bought my 8" brake/shear from Harbor Freight I cut aluminum and brass on my table saw and band saw all the time. No problem except I didn't use my best blades on the table saw, and I cleaned off all the metal dust carefully. Even with a fine tooth blade, it takes a little work with a file. I find file work an enjoyable and relaxing skill, but not everyone does. I still cut aluminum and brass with the band saw if it's too thick for the shear. I think the limit on the shear is around 0.050". Occasionally, I make enclosures from 0.090.
When I'm making a base for a bug, I cut 1/2" thick brass with the band saw. It needs to be fed slow and requires frequent pauses to let the blade cool. Easier than a hacksaw, but not necessarily faster.
A hacksaw does a fine job for panels too, if you don't mind some filing to get it perfect.
I think the Harbor Freight brake/shear is going to be in my will. One of the BEST tool investments I ever made for this hobby.
Eric KE6US
