You could try this though MEK is a nasty chemical.
http://www.gomog.com/allmorgan/screens.htmN.B. A note from Lenn Nelsen June 2007 A jigsaw will work if you have BOTH side taped and go very slowly. Finish the edges like a fine paint job. Start with coarse and go to finer sandpaper/emory cloth. The pro trick is in the final finishing. Use a product called M.E.K. ( Methyl Ethyl Ketone). Put some on a cotton ball and, run the cottonball gently on the edges of the lexan. Hold the lexan
piece "up" so if you have any drips it will run to the floor or over your hand. This will make the edge as smooth as a baby's bottom. This stuff melts the lexan, so don't get any drips on your finished product or you'll be sorely sorry. It does, though, give you a professional edge. Even though it is simple, I suggest practice on a spare piece before you go to the final finishing.
