Sand enough so that there are no scratches. A small scratch where there is a bending load can cause it to crack and break. Just like a small nick in an aluminum propeller can cause a blade to break off due to stress concentrations at the notch.. A fine file in one direction along the edge works. Dragging a razor blade along the edge also works. Use a unibit for drilling holes. Make the holes slightly oversize to eliminate stress concentrations. A drill can catch causing nicks, sharp edges or can even break the acrylic during the drilling.Try to buy from a glass shop or plastic supplier. The trademark acrylic is not as brittle as the cheaper acrylic sold in big box and hardwear stores. And once you get it cut to the size you want lightly sanding a chamfer on the edge before installing will make it twice as hard to break
Glenn
Interesting I will need to give that a try.Drill? Pass. Use a small soft copper tube and sharpen the edges. Heat with a torch and melt the holes. You can do several before the heat gets to where you hold the tube. No cracks. Ever.
Drill? Pass. Use a small soft copper tube and sharpen the edges. Heat with a torch and melt the holes. You can do several before the heat gets to where you hold the tube. No cracks. Ever.