Reply by Vulture

Thanks, Rogue! Kimball made a similar suggestion earlier. I was a bit concerned that it would be asking a bit too much of a pattern bit (I have a nice 1/2” shank pattern bit) to chomp out a cut between the two templates since it’s usually used as a “clean up” bit. However, based on your experience, and Kimball’s, I think I’ll give that a whirl.

I agree on the “over complication” item as well. I mentioned that I had already chopped off one of “the router lady’s” other steps, which just seemed to me to be a waste of the original pattern. Always have liked the KISS principle, even though it seems I rarely follow it!

Again, thanks to all who have shared their experience and wisdom on this topic. I really appreciate everyone’s willingness to help.

-- Kevin, Vancouver, WA