ORIGINAL: dOWa423
I would personally not use the razor blade scoring technique. What you really need to do is buy some curved tip Lexan sissors. See link:
http://cgi.ebay.com/ws/eBayISAPI.dll...sPageName=WD1V
They are made special just to cut Lexan. Then you can use sandpaper to smooth the edges.
You should also get an Gouger for the body holes.
Here is a pic of mine before spraying. [8D]
Is there any particular reason why you wouldn't use the "razor blade scoring technique"?
Just for further clarification, I use an Xacto blade, not a straight edge razor blade. I've used this method since the mid-eightes. If you have good control with the blade, you won't have any problems such as accidentally moving too quickly and scoring the across the door or something like that. Xacto blades are cheaper than a pair of scissors. Blades will go dull as will the scissors.....
The scoring method is very clean. When done properly there is no need for sanding....