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I made Lexan windshields for my old race car, and found that the roto-zip or dremel was way too fast and hard to control to not melt the edges. If you are cutting straight edges only, you can actually use a very sharp utility knife and eventually slice through. Tedious work, but you will see a result that is next to perfect. Since windshields are not all straight edges, I had to come up with a way to make the curves as well. Place your sheet between two pieces of aluminum flashing then clamp and tape the whole thing together securely. The flashing will prevent splintering of the Lexan edge. Why not use plywood? Because you must use a metal cutting hacksaw blade and it will get clogged if you have to cut through plywood. Wood cutting blade teeth are simply too large and ruin your work. If you are cutting a small amount., go ahead and use your hand hacksaw, but if you have large amounts, you will want to get a variable-speed jig saw like [url]http://images.lowes.com/product/039725/039725017932.jpg?wid=158&cvt=jpeg[/url]. Run the saw slowly and do not force it in the Lexan. Replace the blade often, and make sure that it is kept free of aluminum swarf. Hopefully this helps. Remember, my techniques were for an item much large than would be used for a scale model, so unless you are using Lexan as part of your benchwork, you will most likley have to modify my methods to suit the size of the end product your are looking for.
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