Hey Al,
What is your process for fabricated the plexiglass. Do you have it cut or do it yourself? Do you buy large sheets or smaller pieces one pedal at a time? If you do make them yourself, what tools are you using to cut and round the edges?
I got the plexi off ebay, A4 size. It is actually quite easily DIY cut and filed into size and shape. Take a look at this tutorial>
http://www.diystompboxes.com/smfforum/index.php?topic=66840.0
I buy it in a 600x800mm format, usually, and cut it myself, simply because it is faster and cheaper...
Makrolon (Bayer), Lexan (Degussa) = PC Polycarbonate
Altuglas (GEC-Alstom) = PMMA Polymethylmethacrylate
For our use, these 2 common variants are similar, and yes, it is actually quite easily DIY cut and filed into size and shape.
To cut it, I use a jigsaw, or a blade press.
To put it a the exact size, I use a plane.
To drill it, I use a workbench column drill machine.
I use it on the top of the box - never thought using it underneath, but it is a good idea for a lighted version - I just would in this case add an invisible shielding.
See an example of one of my top box lighted plexi :
