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I'm making a new body template. Is standard plexiglass ok, or should I go for lexan?
What is the best way to cut and shape either one of these?
Thanks.
-j.

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“If God dwells inside us like some people say, I sure hope He likes enchiladas, because that's what He's getting”
-jack handy

IMO plexiglass is fine.  Lexan is nice, but much more expensive, and bullet-proof.  They both scratch pretty easily anyway.  It cuts pretty well with a bandsaw, or actually with a fine / bimetal blade on a jigsaw.  It shapes nicely with a sanding drum, but not too fast, and keep it moving to reduce melting.  Others, with more experience, will probably have better suggestions.

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Waddy

Photobucket Build Album Library

Sound Clips of most of my guitars

Make layout templates from 1/4" Plexi, and working templates from Garolite phenolic from McMaster Carr. If you bugger up the working templet...and you will...you can make another from your layout template.   Yes, you make templates to make templates, and if you're smart (which I'm not) you'll make duplicate layout templates and keep them somewhere other than in your shop.   Do as I say, not as I do!

1/4" plexi. If your making smaller templates, (bridge, fingerbd. headstock,etc.), I make a template from masonary bd. Then with double sided tape, I stick a rough cut piece of Plexi cut about an 1/8" larger on the band saw, to the template, and pattern route it on the router table. clean up the cut sides with sandpaper down to steele wool, buff, and you have a factory looking template. I use 3/8" for router bases. (see pic).Here's just a few templates I have.

I have made many templates from Plexiglass and have always found that routing works best. I follow the same practice as Mark and make a template from masonite and then use it as a routing pattern template for the plexiglass. I also recently started experimenting with flame polishing the edges using a propane torch which produces a nice clear edge and works especially well on plexiglass fixtures (not all that great for templates).

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Brad
Avon, OH