The polycarbonate was a piece I had laying around and I didn't bother trimming the edges yet since it's not sure to what size they're wanted to.
I really would like a CNC machine for jobs like this, it's easy to get distracted and lose count of how many revolutions of the control wheel you already did and suddenly you have cut 1.5mm (75 ticks per revolution of the control wheel and 0.02mm per tick) too wide somewhere...
Someday I'll see if I can get http://linuxcnc.org/ setup with this mill (need to get some steppers and stuff first though)