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Message: <blockquote data-quote="Moe Lester" data-source="post: 6478696" data-attributes="member: 551478"><p>like bassmechkanic said, Pre cut it with a jigsaw first, within about 1/8" of your desired final piece, and be sure to leave the corners round. there are blades made for cutting things like plexi and other plastics. then build a template out of MDF and use a flush trimming bit on a router to cut it. This is going to leave you with the cleanest edge compared to plunging a circular saw into it, or trying to jig the whole thing out. Sanding on plexi does in fact work, if you want to frost the edges and have a light illuminate the frosted area. An extremely fine grit paper can be used on the cut surface to smooth it up a bit, but with a router and flush trim it wont need much. Flame polishing the edge can also be done, however just a tiny tiny bit too much exposure to heat or flame will cause the plexi to get small bubbles and warp.</p></blockquote><p></p>

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