Plexiglass

A hole saw works well. I like to cover both sides with blue painters tape and clamp it down without cracking or breaking it. Down run your speed too fast, you don't want to create too much heat and melt it. You can also sandwich it between two thin pieces of wood if that makes you feel more comfortable. It's always nerve racking for me.

It depends on how accurate you need to be and how smooth you want/need the final cut to be. The forstner bit will give the smoothest and most accurate cut, but a hole saw will do a less smooth/accurate cut. Either way, just as the spur of the forstner bit pokes through, flip the sheet over and finish the cut from the other side. Do it a similar way with the hole saw only let it cut about halfway through and then flip it over putting the center bit back into the same hole.
Taping and sandwiching are also good ideas. Drilling with the drill press with the work piece securely clamped is always good.

The best result would be from using a plunge bit and rout the hole using a template.

Thanks for all the ideas.

A hole saw works well. I like to cover both sides with blue painters tape and clamp it down without cracking or breaking it. Down run your speed too fast, you don t want to create too much heat and melt it. You can also sandwich it between two thin pieces of wood if that makes you feel more comfortable. It s always nerve racking for me.

- northwoodsman

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Yep, i have done the painters tape(or leave the sticker on that comes with), holesaw. Spin the holesaw forward JUST to get the pilot through, then run the actual holesaw backwards to start the cut, flip it over and do the same, then slowly go forward til through. You may need to stop and let it cool a couple times.

is it worth building your own?
https://www.amazon.com/Ryobi-A99HT3-Installation-Mortiser-Template/dp/B08DZ1HNZ5/ref=sr_1_2?keywords=Hinge+Mortise+Jig&qid=1650517976&sr=8-2

Here's the hinge mortising jig I'm building. It's pretty cool.

is it worth building your own?
https://www.amazon.com/Ryobi-A99HT3-Installation-Mortiser-Template/dp/B08DZ1HNZ5/ref=sr_1_2?keywords=Hinge+Mortise+Jig&qid=1650517976&sr=8-2

- sunnybob

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I've got the $300 porter cable mortise jig, great if you're doind alot of same doors at once but for doing a door or two I just freehand with lam trimmer and straight cutting bit. Mark out hinge, go around outline with sharp chisel to avoid blowouts. Works fine