What a Hole!!

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scubapro50:
take it to a "glass shop" and have them cut it for you .... it will only cost a few bucks and they have a better chance of not screwing it up !

Or go back to where he bought the lexan and have them do it. But what fun is that?? No cut fingers/hands, no stuff in the eyes, no plastic curlies in his hair. Certainly not the DIY that I grew up with. :eyebrow:
 
ScubaSarus:
How about a drill with a door knob hole cutter bit ?

They're called hole saws and they not be available in all sizes. Using a hand drill can be very difficult ... but not impossible. If you want to cut a disc, you won't be using the center drill and that makes it difficult (the saw tends to "walk"). However, if you're going to have the hole in the center anyway, it's relatively easier.

The other way is to find a plastics center that sells loose pieces of acrylic or delrin .
 
If you want a circle, for say making a lens for a camera housing, you can trace the shape with something the diameter you need, and then cut it roughly to shape with a saw capable of making the cut, then sand the edges to fine tune the shape you need. If you are just trying to cut the hole, rough cut it, then use a sanding drum (attached to regular drill) and grind down the edges to get the perfect circle
 

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