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I need new plexi
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Epyx:

--- Quote ---what about lexan?  I heard that was much easier to work with.  Even when I go to drill holes in plexi, it cracks.
--- End quote ---

Think of it as plexi and lexan being two different langues but the router speaks them both. The router will make short work of either one with the right bit.  The cracking really only comes into play with conventional drilling/scoring etc. I usually use a small forstner/spade first then just trim flush the hole afterwards.  That way even if it were to crack a bit you would trim out the crack with the router bit afterwards.
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