I would not use Plexiglas...it will crack too easy. If you want it to be durable and clear you want to use Lexan. Lexan is bullet proof and can be cut easily, bent like bendable aluminum, s/s, or plain sheet metal. You can sheer .125" lexan and also bend it in any sheet metal break and it will not crack or chip at all. Drill, tap, screw, rivet will not matter they all will work. Plexiglas is very brittle and is best glued together. If you drill and tap it unless it is very thick (.500" and up) it will eventually crack. We use both quite a bit at work in our electronics lab for various enclosures and covers around High-Voltage. I have machined up to 4" thick Plexiglas for mechanical fixtures when metal can not be allowed...usually for non-magnetic environments. Trust me I have a good bit of experience with both.

If you use aluminum you want to use 3003-H14 or 5052-H32, these are both bendable. If you get 6061-T6 or 2024-T3 they will not bend, they will break. If you need to weld it get 6061-T6 and 2024-T3 is good for panels.

Scott

Scott 2000 Contour SVT #1464 Mustang Dyno: 171.6hp/145.3lb Dynojet Dyno: 171.1hp/148.9lb 1989 20th Anniversary Turbo T/A "Indy 500 Pace Car" #1376 of 1550 All Original, 46k with a few mods 2002 F150 SuperCrew