Diggin Jiggin - we have some misc shaped pieces of 1/8" clear polycarbonate if you want some pm me an address and I pop some in the mail for ya dude.
Keep in mind that polycarbonate is extremely strong, however, petroleum products will break it down/crack it.
The only thing acrylic is good for replacement for glass on picture frames. You can get it optically clear so you can shoot lasers thru it.
I've seen some builders use phenolics as lip material - much thinner and stiffer. G-10, G-15 for example or even micarta.
I don't make plugs but I do make just about everything else for work.
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