Thank you for the replies.
Well here is what i am wanting to do.
Take a piece of 1/4 acrylic and cut a rectangle out with the internal corners being rounded out.
I tried first using drills and forstner bits to get the corners. Then tried cutting the pieces between the holes on the router.
In this case i could not use the bandsaw.
I am looking to have a perpendicular edge when done and looking to have duplicate round corners on the interior of the rectangle.
Also looking to be able to be precise on my dimensions.
Not sure i can do what i want with what i have as tools.
If i was simply cutting a clear base for my router i would not be that concerned with dimensions or edge finish but in looking to use the acrylic as a template after i need it to be smooth and clean cut.
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The secret to routing this stuff is cooling.. It will melt and that's where the problem comes in. Also the chips get caught and remelt..
Some things that help and practice or test before you use your good piece.
Cool ..... a stream of compressed air directed at the bit will often be enough to make you successful.
Use a 2 fluted bit so there is ....more time for cooling between bites.....
Cut it out rough then make a finishing pass..this gives chips room to get out of the way and more time less time per revolution to heat the bit..
Sharp bit so it cuts rather than tears off the acrylic.
I have even seen it suggested that you cut in a pan of water for even better cooling...
I found the biggest help was having room for the chips to clear. Once you start melting you are done...
Chatter marks can be cleaned up with fine sand paper and flame polishing..
For cutting you can use a scroll saw to remove most of the waste and then a template and router for finish cut...
What you are doing is treating in more like metal work than woodworking..
Here is one example of actual work being done. Notice that all cuts are only trimming and the chips are flying.....
http://www.melevsreef.com/acrylics/routing.html
And a you tube video showing how easy it is..
Again notice the chips a flying no place to wedge and get hot..
http://www.youtube.com/watch?v=dqoQRtFnFZM
Good luck...
Garry