Step 1: Supplies
cutting tool (I have used a scroll saw and a mitre saw and found the mitre saw better for making straight cuts of small material)
piece of clear Lexan, about 1/2" thick or thicker
Clear Lexan: I got mine at my local autoglass shop. I just asked for a scrap of the thickest clear Lexan they had in stock. They haven't ever charged me for it - but I would expect it to be just a few dollars if they did bill me. And I get 6 or more blocks from one scrap, depending on the sizes I want.
Step 2: Setting Up to Cut
3" x 3"
1" x 4"
2" x 3"
3" x 4"
Step 3: Block Creation & Finishing
Using your cutting tool (I used a mitre saw), cut along the marked lines to make your Lexan blocks.
Sand the edges (a palm sander is quick and efficient).
Clean the blocks in warm soapy water to remove dust and residue.
Your blocks are ready to use. Enjoy!