Adding a flat side to a rod?

[matteekay]

Hey all,

I have a 1/2" diameter aluminum rod and I need to flatten about 1" of its length to get it to mate with a flat surface. Alas, I don't have a mill, but I do have the usual assortment of small tools you'd expect (vises, files, saws, Dremel, etc). Any advice on the best way to do this and get a clean(ish) edge?

[grendal50]

Mark it out, then rough it out with a dremel and finish with a flat file.

[jerryjjackson69]

I was thinking you could drill a 1/2" in hole in some wood, then cut the wood lengthwise revealing as much of the side of the hole as you are wanting to flatten. You can then put your newly crafted jig in the vise before getting after it with the dremel and file.

[CommonCold]

If you have a bandsaw, or hacksaw, you can cut down the side of the rod, then dremel and file smooth.

[punkncat]

If you have a belt sander I would probably jig it up to a bit of wood with a clamp, vice jaws.

Otherwise I second the idea to mark and cut with a saw/dremel

[matteekay]

I completely forgot to double-back on this!

I do have a bandsaw but it's pretty terrible (the deck isn't straight, and the blade isn't perpendicular). Anyhow, it worked well enough for this project; I measured a straight(ish) cut off of the blade, clamped a square dowel to the deck to act as a guide, and did my cut. I added the perpendicular cut with a hand saw. Worked well enough for my needs.