I bought a 1/4" tinted plexiglass, it was cut and packaged perfectly. I shaped it with a wood cutter (slow) and it cuts easily with no splinters or melted edges. what I then filed the edges rounded, no problem, I drilled the mounting holes with real plexiglass drill bits, but it might also be possible to use normal twist drill bits in a power drill (they can sometimes grab split plexiglass too. It was a very solid one Piece of tinted plastic that makes a great sun visor.
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