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idahodale said:
If I understand you correctly your bushing is too long. When I have run into this problem I trim the bushing to the desired length. I use 1/4 inch masonite for some temlates so I do a lot of trimming of bshings.
Some guide bushes are too long But I think your problem is your templates are too thin Try making them from say 12mm MFD or even 9mm MDF Standard guides will do both Remember you will loose some of the depth of your guide when it is fitted to the router and in most instances the guide will only protrude about 8mm
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