You want to be very careful when cutting plexi with a hole saw, first make sure you mask the area where the hole is to be drilled, both front and back, this will add a little strength to it. I clamped my window to a flat board and used a variable speed drill with an 80mm holesaw. You want to keep the holesaw spinning at a fair clip but not so fast that it melts the plexi, the problems arise when you go too fast and then slow way down causing the blade to lock up (melting and then cooling plastic). Do not rock the holesaw if it gets stuck, try reversing the drill to free it up. It is easy to remove any melted plexi from the edge of the hole if you do go too fast, it just snaps right off. Water would keep the plexi from melting as stated above.
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