2040 sawing jig
thingiverse
This is a DIY aluminum sawing jig that simplifies repeatable sawing of 2040 extrusions. Unfortunately, it didn't perform up to expectations with a hacksaw - every cut was non-perpendicular, but at least all the pieces were identical lengths. The code is maintained on GitHub: https://github.com/hyperair/aluex-sawing-jig/. Follow these steps: Assemble with M5 screws for a customized cutting length. Begin sawing as straight as you can, focusing on making each cut perpendicular - my attempt failed miserably and I spent $10 getting it CNC-cut instead.
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