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I'm unclear what you are trying to do Kevin. Are you cutting off section or routing a channel in a piece or smoothing an edge that's been cut or routing a profile or ??? How much material are you trying to remove?

 

In general I try to use spiral bits, they cut a lot better for me than stright bits.

 

Anytime I cut plexiglass or lexon (with a table saw) I end up with plastic bits everywhere but in general it cuts okay, but it's a messy as can be.

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