Thanks Jim!
I have much to learn about working this material. Thanks for the drilling tips.
The only drills I have at 90 degrees are the spotting bits. I've noticed I get cracks when using the other points as you mention.
Cutting the first batch I'd used the chop saw with 40 teeth. Was recommended a blade for plastics or one with a specific tooth rake profile to not melt the acrylic. Was told there was one that was 96T and a 135T range version like the veneer finishing cut. Today cut some more rod on the bandsaw with a 12TPI blade. It melted as expected but wasn't to bad. The kerf is much thinner so I'm not wasting as much material.