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You sure it was aluminium ? Hacksaw should easily whizz through that . I normally cut round objects in a 'V' block, they can't escape or move. One of those fine tooth hobby hacksaws then just a big sandng block to finish it off smooth and square, tidy it up with a small file on the corners\edges. 10 mins max. I normally wrap some tape around it to establish the cut line.
Etch and paint is seperate.
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