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Plexiglass is an acrylic and lexan is a polycarbonate. Lexan melts at a much higher temperature and is quite abit tougher and scratch resistant. Use the thinnest you can get away with probably about 1/8 inch. It will have to be uniformly heated to quite a high temperature as it melts at 600 degrees. Make sure every thing you use as a mold is absolutely clean. I would mold it first and then mark and cut it if I was using a rear window for the mold. Cut flat it may not fit when made to curve as it will be to short. Hope it helps.
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