Questions for LED accent builders

Alright guys, I'm gonna start making some LED rings for some of my customers' boats pretty soon. I've experimented with a few things so far:

For cupholders, I've put a single LED facing up in the drain hole of a cupholder, sealed it, then covered with a lens. The lens was cut out with a hole saw, sanded smooth to look frosted, then sealed in. The center hole was plugged with a white nylon cap. It's decent, but could be better. I have pics, but they're not uploaded yet.

I'm considering building a router table. I've already got a 4X8 rolling workbench in the shop, so I'm gonna integrate a router into it. I'll top it first with a full sheet of 3/4" Melamine, then I was going to pick up a Rockler table plate (http://www.rockler.com/product.cfm?page=21299&filter=router%20table), and a Craftsman Professional 2 1/4hp router. The router would be at one end, upside down, mounted with that router plate. Let me know if I'm on the right track.

I chose the CMan router because I'll probably only use this on the table. I have a smaller trim router that I use sometimes also.

What's the best way to cut out these lenses or make LED rings? I use Oznium's LED's so that's covered. Also, how are they frosted? Just by sanding them with finer grit sandpaper? I used a sandblaster on one, but the finish was too coarse and it left the plastic looking brownish.

I think I've seen where some shops have CNC machines to do this with, but that's more than I intend to deal with.

Any help is appreciated. Again, this is for local customers of mine. They won't be marketed or sold online or here.....

can you get that plastic material in round stock, what about a bench lathe?

I've been using sheets of lexan, it's hard to find anything else around my small town. 1 of my distributors sells plastics from Select Products but it's fairly expensive so I haven't ordered any yet.

Craftsman makes light duty homeowner tools. Go with a Dewalt.Bosch or Porter Cable you will be much happier with it.

John,

I sent you an email. I'm having email issues right now, Outlook is telling me every message is undeliverable, but they seem to be going out. If you dont get it, let me know and i'll send through PM.

Michael, I've been researching all of them, and the Triton was the first choice, but I really don't see spending $220 on one, when I can get the CMan Professional for $130. I've seen some good reviews about them, but you know what they say about opinions. I looked at the CMan router the other day and it looks to be built pretty well, even compared to the Porter Cable, but then again I've heard that the PC's are relabeled Firestorm's.

Tigemike, I didn't receive an email. Try again

PM sent!

Got that one, thanks!

I use a dremal, with a hole cutter adapter. and a rotozip bit