This is a typical example for the use of the template guide and a straight cutter taking 4-6mm cuts in the plunge mode. You can still use your original template all that will happen is your final shape will be slightly larger than the template. Try a 3/8" cutter with a 5/8" template guide this will increase the size by 1/8" and I do not see that a problem If it is then reduce your template by 1/8"th before you commence.I would also suggest you make yourself a a router support to kee the cutter perpendicular to the face of the material.kak047 said:I tried you suggestion, but it was not successful for me. This project may have to take a change in design.
The photos were great in making and the forum is excellent. Thanks for the help.