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Drilling button holes in Plexi/Lexan?

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Knievel:
Router is the way to go for sure. You can get a plunge bit that will allow you to drill though and then route out the hole.

If you don't have one I would recommend using Lexan instead of Plexi with drill bits.
It's a softer material and should drill easier, and without cracking.

BobA:
+1 for the router and trim bit.

kelemvor:
Do I need to run the router on a slow speed or can I let it crank?

BobA:
Run it at regular speed and the plexi will cut like butter.

monkey puzzle:
I used a hole saw for all my button holes with no problem. Have the drill on a high speed, but apply very little pressure. If you want to be cautious sandwich the plexi between 2 peices of plywood and clamp together. Take your time and don't try to rush the drilling. Do a few practice holes first on spare plexi.

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