Wow, a mamey nomination before I even have final pics - I'm flattered! I can't wait to snap some final pics and show off some of my details now! Still trying to figure out some sideart and stuff to do; got a few ideas brewing, just gotta act on em...
Zakk - to answer your questions: I was originally going to use a dremel (i've got a flex shaft for mine that makes it a bit easier to be precise), but because of the amount of small details and all straight lines, I didn't like how it looked with my smallest engraving bit. Also, it is extremely difficult to get uniform depth on the engraving with a dremel used this way. I'm going to try using the dremel on wall sign that I want to make, and I want to try using the router base to keep a nice uniform depth on that; I'll be sure to keep you updated on that - I might even write up a tutorial on plexi engraving highlighting the different methods you can use. As far as my current procedure, I just print out my pattern (best to mirror it first, so you can keep the engraved side on the back, and therefore make it easier to clean), then spray mount it right to the plexi. I then just cut along the lines with my exacto, right through the paper and into the plexi. If you use the right spray mounting stuff (the temporary stick stuff), you should be able to mount right to the bare plastic. If you're uncertain, just leave the protective plastic on the plexi, and mount your template on top of that; it doesn't impede the cutting at all, just makes the cleanup a bit harder. Almost forgot to mention - when doing this with an exacto, you're going to break the very tip off the blade within the first few cuts - DON'T REPLACE THE BLADE - it actually works far better when the tip isn't razor sharp; the knife doesn't slide around on the plexi as much then, and you get much better control of it. Just be sure to take your time; one slip up and you'll either have to live with your mistake, or start over. Drill any holes that need to be drilled in the plexi BEFORE you start engraving. Start with the hardest/most detailed part of the engraving first, so it won't be as bad to start over if you make a big slip up early in the work, as opposed to at the very end. Good luck!