I use a 4x6 bandsaw too, but it's pretty slow going. If you're only making an occasional blade an angle grinder with very thin cut off wheels is the way to go. I bought some on sale at Atwoods (farm and ranch store) for about $1.00 ea. and you can cut out 2 or 3 blades per disc, maybe more. If its a simple profile, even with the saw I'll still opt for the thin cutoff wheels just because its so much faster. Because of the heat, just leave a little extra meat at the cutting edge.