At the VEX World Championship, our team failed inspection as our lexan was measured to be 0.01" thicker than the 0.0625" thickness limit. However, the lexan we purchased (from a local hardware store) was sold as 1/16" lexan. This was most likely caused by normal manufacturing tolerance of the lexan, causing it to be slightly thicker than listed size. However, the inspectors said that we needed to buy new lexan, causing our team to waste our first 5 hours at worlds tracking down a team that had lexan, a team with tin snips we could borrow, and a team with a drill we could borrow, and then carefully retracing each piece onto the other team’s lexan and re-cutting and drilling all the necessary holes.
Our school’s other team at Worlds used lexan cut from the exact same sheet as ours, but passed inspection.
Is there some leeway in the limit for lexan thickness? Or are teams expected to bring calipers to the hardware store they buy lexan from, and carefully check the thickness of each sheet they buy to ensure it is not 0.005" too thick?