I bought some supplies today to attempt my own 4 to 6" wakebaits. Going to be attempting to copy the mini slammers and generic rats primarily and also some of my own designs. Anyway, my question is I bought a sheet of .08" thick lexan for my bill material. What tools and techniques are best for cutting this into a lip shape? Searched a little bit but didn't come up with much.

Just read the swimbait sticky. Nevermind.

Success

I'll revitalize this now that I have better questions haha. I've finished the shaping of my knockoff mini slammer and now it's time to start on the joint and the lip. A couple of questions.

1) Any guidelines for lip size/dimensions? Lure is 4" and about 1 1/4" in diameter.

2) About how far back from the nose should I place the lip?

Since I'm shaping all of these by hand with sandpaper I'd really like to try and eliminate the guesswork. Any help would be greatly appreciated  

For a 4" lure I would have about 1" to 3/4" exposed lip and have about 3/8" to 1/2" glued into the bait. Making it a little long you can always cut it down a little as needed.

If it is your first try I would not epoxy the lip in until it's tested just cut the lip slot tight and it is easier to make adjustments.

Also on a first or trial bait I would make palces for 2 or 3 different line tie positions for testing, you will most likley find one of them is going to be a lot better than the others in action.

Just think of your first bait as the test model and do not worry about finish just a coat of sealler on the wood so it will not absorb water and when you get it with the action you want then it will be easy to duplicate for the real thing.