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Originally Posted by Phil Paspalas
Last season, our team used Lexan (polycarbonate) to shield the electronics from damage. We found it easy to cut, bend, de-bur, and generally pretty good stuff! But it's a pain to drill!!!!!!!!!!!!! Especially when trying to drill large holes in it to remove weight. We tryed a hole saw with poor results and regular twist drills were problematic as they get past 3/4". Any suggestions? 
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When doing any type of drilling in Lexan, it is best to leave the protective paper coating on (both?) sides. This prevents most cracking, and allows a cleaner cut/hole to be made.