Van's advice for enlarging an existing hole in Plexiglas is to never use a drill bit but instead use either a reamer or Unibit. I need to drill #40 through the Plexiglas and roll bar, then enlarge to #36. I've done tests with scrap Plexiglas using a regular #40 (I've never seen a plexi-specific #40) followed by a bit made for plastic from McMaster-Carr, the really pointy kind, with great results. These bits make the cleanest holes, either as on original hole or enlarging a hole, I've seen. They're noticeably better than those made using a "modified" bit (drilled into concrete). Am I tempting fate using this method (#40 followed by #36 plexi) on my rear window?
Jerre
Jerre
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