First shot at custom chassis.

[lincpimp]

A 20 dollar walmart special jigsaw with a coarse tooth blade will be the best way to cut lexan/plexi that thick. Not really sure if that is the best material to use for a chassis... That being said I do have a few bombproof chassis and I know that MM has a fondness for clear plastic! As far as that pede chassis goes, use some 1/2" al angle and screw it along the sides to enhance the rigidity. You could actually ues that to make the sides for the battery tray... 2 for the price of 1!