Extremely toxic? After a quick search I found that about 2% of the people that were inhaling beryllium dust over a period(worked with it daily) developed CBD, a lung disease(not cancer). Most of the infected got it before it was know that it was toxic, and a effectiv "safety rules" were available.
My sources say that it's "very toxic".
Can you post the link to your source?
Beside inhaling you also shouldn't touch it, because it may lead to contact dermatitis.
The danger for the health was the reason why Beryllium is forbidden in the Formula One since 2000.
Well, there are different sources selling it, but if they are willing to sell at a low-volum order I don't know. Pricey, yes I know!
They might be willing, but Beryllium is a so called strategic metal and I guess you need some documents to get alloy plates.
It's primarly used in the armament industry and in very small amounts for springs in clockworks.
I also red that CNC-machining left only big pieces, and no small airbourne particles you could inhale. And a finished product was not dangerous.(don't need a durable coating.)
I wouldn't trust this. This might be correct for Al or CrMo, but I don't know if this is the same on Be.
Addtionaly I've no clue if special tools are needed to cut Be.
AFAIK Chris Hinshaw (the founder of Beyond) did clear coat his frames.
One of the reasons that his Be frames were only available for a short period was his concerns about the durability of the clear coating.
A single crash would have been enough to scratch Be particles off.
You mentioned brake rotors. How do you prevent people from inhaling particles?
Chainrings do also wear over the time.