Hi

As an absolute novice, I'd be really grateful if you guys (and girls) could
help me out on how to cut small plastic (acrylic) mirrors and some practical
advice about what equipment I need to buy.

As background, I run a small ceramic/pottery shop and want to make some
hand-held vanity mirrors. I have sourced a supplier (around £80 for a 8' x
4' sheet, 3mm thick) but the cost of them to cut the mirrors for me is very
prohibitive and so I need to cut (and finish) them myself. Ideally they need
to be oval (aound 5" x 4") but if this is difficult then a 4" diameter
circle might be acceptable. I need to make around 50-100 at a time and they
need to be identical (or at least very close to identical) in shape.

I have done a Google usenet search and there are many suggestions of ways
that 'work' but unfortunately I don't understand the equipment they are
talking about (piloted flush cutting straight bit / carbide tipped combo
blades and so on) Suggestions have been made for band saws, jig saws and
circular saws but I am not sure how or if any of these could be used for low
level 'mass' production. I understand that there may be problems with
friction heating of the mirrors and fumes.

Any advice or practical tips in something close to laymans terms if
possible, on what equipment I need to buy (feel free to mention product
names) and how it should be used to cut / finish the mirrors will be very
gratefully received.

Many thanks and kind regards

John