Lee,
Remember that Lexan is 30X stronger than acrylic and over 300X stronger than glass.
Thus that 1/2" thickness should be strong enough. Although I can see one possible problem, the taper on the end of a standard drill bit will make it harder to drill deep enough for a good strong seal for the copper if used as I envisioned.
If you cut a slit and then hand file it with a small hand file to take the tapered down copper tube the lexan will be enough with ease. Just load that tapered opening with plenty of expoxy. While getting a good tapered copper opening may take some time and patience I can't imagine that it wouldn't perform with exellance.
Your data shows strong promise, good looking out man. Be interesting to see how much a nicely tapered copper inlet can improve it even more, but you've already kicked that exo block to the curb.
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