[Gdeaver]

This summer I replaced allot of trim on my house using expanded PVC boards. You can buy this material at most lumber yards. I had no problems with the router. You didn't mention the application. Expanded PVC is relatively fragile compared to other solid plastics. In the future you may want to explore molding processes. It takes time to master the process, but really isn't that hard. My Wife gets very upset when I use the oven for vacuum forming.