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Saw your pics, well done! As for the cutting, great question! I originally tried a table saw which didn't seem to work well, but might work better with a different blade. I use a band saw now and...

Yeah, I'd love to see your pics, I am thinking that I was not doing enough sanding. I'll follow your lead and try again.

Still, no luck. I used a wagner power stripper which worker better than the butane torch, but I still get bubbling before the plexi smooths out no matter how slowly I have tried. I guess I just...

Yeah, I saw your worklog yesterday again which made me think to try it. Hmmm... I have a heat gun paint stripper here that I have never used before. Maybe I'll give that a go.

New question, how does the flame sanding thing work? I tried it on a little scrap with a butane torch and kept the flame away from the plexi using only heat, but as soon as it began to heat it...

We had discussed this earlier and there is some question as to how well it sticks. Please let me know how it works for you because if it works good, I may go this route too. Thanks!
Jon

That's a great idea, thanks again Tybrenis!
Jon

This is a great tutorial everyone, learned alot from reading it. I did my first experimenting with plexi this weekend and I just sort of walked in blind, I wasn't aware of this tutorial yet. ...