[lukevanoort]

Acrylic/Plexiglass is pretty much the bane of my existance when doing electrical work. Thin acrylic shatters when drilling (except when drilling with fine-toothed holesaws... that's the only thing I have found doesn't shatter it), it shatters when cutting, it shatters when bolting, and it shatters when you look at it the wrong way. We used a lot of 1/8" acrylic on our 2006 robot (hopper walls, electrical board, and a few other things), and most of us decided never to use it ever again. Polycarb/Lexan is much easier to work with. It still shatters if you drill it really funkily or tighten a bolt too much, but it is nowhere near as bad as acrylic. I have even pop riveted 1/8" polycarb (which, I imagine, puts a lot of force on it) with no problems. Just use polycarb instead of acrylic, the cost difference isn't that bad, and it is much easier to work with.