Hi Tom,
I'm glad you were able to see the video OK.
I agree with you on using a straight bit to cut out most of the center... finishing up with the bowl cutter (I think I mentioned that in my first post).
My VERY FIRST thought was to cut each plank BEFORE the glue-up using a jig like yours to force good registration. Any ole straight bit could be used, etc. with a template and guide bushing. Then glue them together and finish it with the Bowl cutter with extension, etc.
... I just thought that the outside trim could also be done while unglued... that would cut down on a lot of extra work... wouldn't it? What do you think of the unglued approach?
I'm not sure what you have against the bandsaw, sanding, & routing the edges... Harry did the same thing except it was just bottom 'holding' strip he cut with the bandsaw after routing down the outside edge. Is the bandsaw off limits? If you like the routed cut finish, why not cut the biggest part off with the bandsaw, then go to the router to finish it up...? ... leaving only a small amount of router cutting.
Good luck on your DVD's.