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.