[maclaren]

Plexi-glass I.E. Acrylic is EVIL it shatters even before you are finished machining it. Therefore it should be avoided like the plague. If you are put into the circustance when someone has a knife to your throat threatening to kill you if you don't use acrylic then the only answer is to use brad point drill bits. But that's about all you can do; Don't mill it, turn it, cut it with a saw, or do anything else because it will break.

However do not dispare there is an answer.

LEXAN, POLYCARBONATE is the answer!!

Tough, Strong, Clear, some varieties are bullet proof. But all varieties of lexan are better than plexi-glass.