Best way to cut wheel spacers?

In order to finish my GS1100 swingarm swap, I need to cut down some 7/8" spacers for the rear axle. I've been trying to think of a way to cut down the spacers I have, as they need to be 11/16" length and cut as square as possible. I'm broke, or else I would turn to the machine shop to do it for me. I know there are people out there who cut down wheel spacers on their own, but I'm not sure how they do it and get a square spacer in the end. I have some tools available such as a cutoff wheel and air powered hacksaw, but neither is really practical to make a perfect cut. I'm interested in seeing some of the ways that any of you have cut down a spacer, without using something like a lathe (which would be nice to have). Let me know, because I want to ride my bike again! Thanks!

When i was in school learning to be a machinist onr of the first projects we had involved squaring up a piece of stock that had been cut with a band saw using just a file. The filed ends had to be square w/i .010 over like 3 inches. Cut the spacer as close as you can and leave a little to file. Use a good square to check as go.

A sharp file can really remove metal if needed. Files only cut in one direction, but for heavy removal draw filing can work well and will leave a smoother surface.

or u could try a grinder with a flap wheel.

I agree with the hand file approach.
Tip on technique: Set a micrometer or caliper to the correct thickness and use it as a "Go/No-Go" gauge. Check frequently as you file.

If you're going to try freehanding it with a hacksaw, at least make a jig to get your angle roughly correct.

I have not tried this yet, but I always thought you could put one of those metal cutting disks for your circular saw on a standard chop saw that you would use for wood. If you took your time I realy don't think it would damage the saw any and also it's aluminum, right? You should get a good square cut from a properly setup chop saw.

What part of the world are you in toadson? Maybe one of us with access to a machine shop could help?

I live in Lancaster,PA
Send them to me and I will face them to length for ya.

Or better yet, give me the dimensions and I'll send you new ones.

Doug. Machine shop and KZ owner

I guess I should have updated this after I figured out a way to sand them down evenly. I wouldnt even know where to begin to explain how I did it, but now I have two spacers that are nearly perfect. I would have had the bike running with the new swingarm, but my chain was a bit too short. Got a new one on the way and it SHOULD be here tomorrow. My next quest is going to be finding some proper shocks, and then figuring ou a chain guard and the swap should be complete. Thank you for the kind offers, this is truly a great forum.