Fugadude: Yes I am useing GE 1/4" lexan Polycarbonate. Its very strong. I am useing the same material that they use in bullet proof shields,windows,etc. It does flew some with double decks there isn't alot. I am very pleased with it. Its very easy to cut and strong.

koolkid: No these are the actual parts. I am not positive what you where useing but what I am useing is not that material. I am guessing you where useing plexiglass or some other type of clear plastic. I tried cutting something like plexiglass and it did what you explained. This material Lexan is exetremly strong and does not crack when you cut it or drill it. Otherwise it would be impossible to make a chassis out of it.
Peace Ethan