#2
with a dremel because it will melt through not actually cut so cracks wont have a chance to form. only thing is that if you do dremel it you're going to have a lot of sanding to do to get the plastic melted things off the edge.
#5
well it is plastic so you cuold get away with a hacksaw as long as you use a fine blade. a jigsaw would also work as long as the blade is fine like a metal cutting blade. but i would definately recomend a dremel if you do alot of diy projects it will come in handy. if you have a bandsaw it will work, but make sure your very carefull (dont cut off your fingers).
#6
when i had to cut mine i just used a stanly knife-worked fine for me
#7
Scroll saws make light work of sheet plastics. They tend to cut the plastic, but then melt it back together ever so slightly, but it's easy to seperate.
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#8
If you find it melts back together use some masking tape over were your cutting stops the friction wich causes melting