How to make a cutout in a lexan panel

[Sammy J.]

I bought a set of rc4wd rear taillights for the Jeep Wrangler. Here is an image of the cut I have to make in order to mount them.

Any advice on how to make this cut?
I am thinking of using a reamer on the four corners, then an exacto knife to complete the cut.

Is there a better way?
Thanks for any input.



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[badhoopty]

little drill bit on all 4 corners and then score between the dots with and exacto, then cut the middle like an x between the corner holes and snap each scored section out. i dont know if thats the best way but thats how i would do it.

[C*H*U*D]

I like to use the X-acto backwards. When scoring lexan, it's easy for the tip of the blade to wander. Scoring with the backside of the tip helps me stay on line better.

And practice on a piece of scrap first to make sure your measurements and techniques are sound. Nothing worse than ruining a body because of a mistake.

[Alexander_0_1]

I'm the same as C*H*U*D, only I cut inside the lines of what I need to be removed, then I take a file, and file to the size I need/want. Just go extremely slowly.

My method doesn't alway work if you need to reuse the piece you removed, I just recently F***ed up an old Nissan Titan body that used to be on one of my savages...it's not terrible, but the line that separates the hood from the fender is wider than I had originally planned

Any decent tool/parts store should have an assortment of file sizes though if you need.