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Finishing an edge on plexiglass...
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stratjakt:
Sandpaper, maybe 150 then 220 then 320 then 400 then 1000 then 2000..  That's silly, you don't need to go that high, just stop when it looks good enough for you (probalby 220, skip the rest).

You can also "flame polish" the edges by heating them with a torch, enough so just the edge melts a wee bit then cools to a nice clear rounded finish.  This takes a bit of practice, since you can easily start burning the acrylic, or melt a bit on the face of the piece.. Once you get the feel of it, it works well.  I've used a propane torch with a really sharp flame, and basically quickly skimmed it down the edge.

Ultimately, though, I'd say a piece of relatively fine sandpaper and about a half hours worth of work would be the best.
pmc:
Presumably all these techniques work for Lexan as well as Plexi? I know that they are fundamentally different animals, but I don't really care about that as long as the same edging techniques work on both.

-pmc
AmericanDemon:
We built a chopsaw stand once and behind the saw, the guy wanted a plexi shield that curved.  So we heated the plexi up with a torch and attached it.  Don't really recall how we attached it, but when the guy cleaned it the first time, he used Rubbing Alcohol.  The sucker cracked into a million pieces.  It was a sight to behold.
Bones:
I cut a hole in some scrap MDF the same size as the trackball hole I had cut in the Lexan and then lined up and clamped the two pieces together. I then used a router to bevel the edge of the Lexan using the MDF as a guide and a rounded router bit that had a guide bearing. The process worked fine and without any problems.

The great thing about this was I could cut it once, decide I wanted to bevel it more and just keep adjusting the router depth until I got the result I was after.

The little dags on the edges are just the protective paper covering, once removed the bevel was very clean and required no sanding.

nostrebor:
I would do it just like Bones said, and the flame polish it. The trick to flame polishing is practice,practice,practice... And low heat. I just use a little butane torch from Harbor Freight.
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