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I like to take a couple of shallow passes to knock the square down some, then go deeper. You can get something like 1/8 inch cuts after that. Last pass is also shallow. I also have the cutter that JTR mentioned. You are also on the other site that he mentioned for the how to on doing up a template (FAQ section, top thread). I have yet to use lexan for a template. I like to turn a body on the lathe, then use that as the template for the dup. If you are doing 100's of plugs, the lexan would definitely be the way to go.
Jigman
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