Hi Stan,,,, I just happened across this thread and I have an idea that might help. Have you tried turning the pattern and the piece over and routing from back of the piece? What I think might be happening is you might be routing against the grain at the point where the wings come together. You might have to modify your pattern to have an index pin or stop on it so you can locate it in the same place on the back side of your work piece. Give it a try. Chuck
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