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Thin Lexan?
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Turnarcades:
You can easily sand or router the edges of Lexan to bevel or smooth the edges, just FYI if you choose to go down the 2mm route.
TopJimmyCooks:
I would try something besides .187" lexan if I build again.  there's really no way to work it except to cut oversize with a laminate trimmer bit, then template and rout it.  Extremely gummy when machined.  After breaking a couple of pieces I barely had enough to finish.

on the good side it is available from lowes and HD in various sizes if you want to check it out. 
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