Re: acrylic joint fitup?
Hole saw are nominal, and will have a runout approx .0625 or greater, depending on how tight the mount is. They do not give a clean cuts, like other do. The most precision way would be with an endmill. I would proably use a fly-cuter. Some fly-cutters hold endmill cutters, instead of the standard insert. These will give you more control. Stay-away from carbides cutters, they require greater interface/force to cut. This is going to be a difficult cut, take your time. As for a cutting fluid, you will have to look and see what's on the market now.
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