I've been using a dremel with an abrasive cutting disk to cut it, then sanding smooth. The only small problem is that it melts a little and you have to trim the melted material with a hobby knife before sanding. Leave the plastic protective covering on as long as possible before installing to protect from scratching. Lexan is soft and scratches easy. It is still the best type of clear material because it will not break. You can bend it double and it will not break. Other plastics will break very easy, even just trying to cut. I think you also may be able to use a sheet metal shear to cut the lexan if you have square edges, but I have not tried this since I didn't have many square edges.