Just a progress note in case anyway takes a peak at this thread. To my surprise (and relief), thus far my testing of the .60mil plexi-glass looks very promising. Cuts well via band saw and seems quite adept to shaping with the ROS. Looks like the ROS can quickly thin it down a bit, as well. And pretty sure I'll be more than content with its structural integrity. If somehow this manages to break, thinking I'll likely have bigger concerns to worry about!

Todd