Damn shame about the cracks. I know how disheartening it is when something like that happens. Good to see you pursevered regardless.
I bought a unibit recently which drills through acrylic beautifully. 4mm-12mm in 1mm increments. I highly recommend one of these for all your sheet drilling (steel, aluminium and plastic).
So as not to mess with ya' thread, I posted two example pics here: http://xtremesystems.org/forums/show...3&postcount=28.