"1. How thick should I get it?"
1/8" on top of 5/8" base (MDF, particle, etc) seems to be the standard - if there is such a thing. This gives you 3/4" total for t-molding to cover.
"2. How the heck do you cut it (my dad's the construction guy, I'm just wondering if he has the tools to do it)?"
Having cut tons of it for combat robots (1/8" - 3/4") it cuts/machines just like wood. As long as you use lexan/polycarbonate and not acrylic or plexiglass it is almost impossible to shatter.
Use a fine tooth sawblade, and go slow on the twist drills because it tends to pull the bit in once you penetrate.
Its really pretty easy to work with - just leave the protective covering on until you are done if you want max prettiness.
