The Diablo 10" 84 tooth blade I mentioned above does not leave any burrs to clean up. Lasts forever too. I had it for like 8 years and it's still going strong. Recently loaned it to a friend for this exact purpose and he was super happy with the results after building 4 rigs.
I mounted it on a cheap ass Hitachi miter saw which costs like $100 or less. Originally I was using it to cut some large 8020 alu profiles a few years ago:
https://www.8020.net and it went through 2"x4" stuff like it was wood.
Later I bought another blade like that for my cheap table saw to cut plastics. It's a night and day compared to the stock free blade that comes with a $100 saw. Good investment in my opinion.
The key difference is carbide teeth welded onto that Diablo blade. They stay sharp 10x longer than any hardened steel you can find on cheaper tools. Titanium Carbide is the way to go when it comes to cutting. They are much sharper out of the gate and stay sharp literally forever unless you run them into some real hard material like steel or carbon fiber and such. And of course sharpness and high speed is the key to burr-free cuts. You can use cutting oil or even WD-40 spray to make perfect cuts even better and prolong the tool life.
Final Edit:
WEAR EYE PROTECTION!Thank you, Thank you, Thank you!
I was at Home Depot this morning and figured what the heck I'll buy it (the Diablo) and give it a go. It is exactly like you said, it cuts the square tubes like a hot knife through butter. All of my cuts are now perfectly square and burr free, I think I have made like 50 cuts already it is so great.
The only drawback, and not really a huge deal, is the small aluminum shavings everywhere. I went ahead and moved my sawhorses outside and set up a wood plank to mount my miter saw on. I am also using a vacuum attachment to the back of the miter saw (instead of the dust bag that was on there) but there are still plenty of those small shavings floating around on the breeze. Just a warning to anyone else who buy this, it cuts slick but there will be small metal particles everywhere so plan on using it outside.
