Made the plexi inserts today, here is a little tutorial
First gather your materials:
Router and router table
Scissors
Flush Trim Bit
3M Double Side Sticky Tape
Plexi Glass
Wooden replica of insert Shape
Here is the flush trim router bit, note the bearing on top which rides the curve while the bottom does the cutting
Put your double side tape on the template, this allows you to stick the template to the plexi glass thus preventing it from moving.
Adjust your height of the router bit in order so that the bearing rides on what you want to copy.
Looks good. You will note I left the protective covering on, this is important as it prevent scratches from appearing on the glass. (The blue tape is because the edge was pealing.)
Begin cutting the plexi
When you are done simply remove burrs with a lite file (If there are even any I had none). And separate the template from the plexi insert
Nice clean edge
Fits great!