I have been buying 3/8" cutting boards at Bed Bath and Beyond and making all my inserts from the plastic material.
It is fairly tru as far as the surface goes, flexs a bit and is easy to work with.
I make router, table saw and any number of other inserts and some fixtures from them.
MSC mscdirect.com
Do you really mean Plexiglas or a generic clear "plastic" sheeting? I would recommend that you look for Lexan (or polycarbonate) sheeting instead of the acrylic that is Plexiglas.
Rockler lists it in their on-line store -
Transparency can be handy but rigidity and impact resistance are more important.
Use a 1/2" Fostner bit to do the corners...
That would give me a 1/4" radius.
Alright, then use a 1" fostner bit.
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