Thanks for that write up OWAL. I need to make a 41qt rack soon but I'm pretty nervous about using the pvc from home depot. Not so much because I don't think I can do it or I'll have problems, but it's a lot of money and I have everything figured out to take 3 sheets, so one wrong cut or if I screw up a panel and I have to pay another 75 bucks. I'm still uneasy with home depot cuts. I've had great luck with them so far where they're more accurate than I'd ever be, but precision wasn't as much of a concern as before. Not to mention the cuts I want kind of depend on the thickness of the blade and everything.
That's what I've read, I imagine it depends on cut speed too though. I used a metal cut off disc on some aluminum window frame and if I went slow the cut would be rough and there would be big clumps of aluminum melted together. But if I went fast it'd cut clean. This was with a miter saw though, I'm not sure if I could use a circular saw at the same speed to cut. Blade quality is a big deal though, it's a big difference going from a >$5 blade to a $20-40 blade.