I have a number of end caps to make up for a prototype kit. At this stage we do not know the viability so trying to make do with existing tools where possible, that said if needed can upgrade blades as required.
Currently using an Evolution mitre saw with the below blade, two problems - firstly the finish is very rough, takes an age to file down by hand which can reduce overall size. The channel is firmly clamped from both sides, tried coming down on the piece (chop saw style) or the sliding option - both more or less the same.
Other problem appears to be a wavy cut, I can only assume the piece is somehow moving during the cut - again, lots of filing leading to irregular edges.
Contacted the folks at Evolution relating to similar problem with plastic channel, their recommendation in below.
Any suggestions greatly appreciated.
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https://www.evolutionstore.co.uk/furyblade255multi.php