you can cut aluminum with wood working tools - just go slow. Its a little scary on a table saw but I've done it before cross cutting a broken pole section. I haven't cut one lengthwise and would be a little concerned about possible tension within the material causing it to pinch down on the blade - go slow.

I cut down some spinnaker pole pieces to make a mold for a GPS mount. I needed a precise bevel for this to mount inside the flat mold pieces.

[Linked Image]
20150128_215428 by Jake Kohl, on Flickr

[Linked Image]
20150131_113405 by Jake Kohl, on Flickr

That said, though, a sunfish boom extrusion (I think it's the boom) is less than $100 and they are everywhere. It's typically the same diameter as our spin poles and more than long enough.


Jake Kohl