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Best way to widen a buttonhole with plexi already installed?

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shponglefan:

Depending on how much material you need to remove, I'd just file it.

epac90:

I thought about that also Chopper.  I'm thinking though if I can go in a downwards motions instead of going side to side, it may help that some.  Will definitely take alot longer, but atleast I wouldn't be working it into the crack between the wood and plexi. I also have the big silver knob for it so it will cover it up quite well.

McHale, Stepper bit would work great, and I know they work much better on plexi than other bits, but if that thing somehow grabbed the plexi or wood and my plexi got cracked I would be heartbroken.  I think I'll take the safe solution and just use some sandpaper.  Shouldn't take much at all with some medium grit paper and a little elbow grease.  I imagine the hardest part will be keeping the underside of the plexi clean.

epac90:

Shponglefan, what kind of file should I use?  Like a round chainsaw file?   

shponglefan:

Chainsaw file is probably too small.  I'd just use a regular half-round file. 

Le Chuck:

Dremel with a drum sanding head.

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