a little more info!?
in order to try to better explain the situation, (i first tried to write a better explanation, but, well..) i attached a picture .. ed, you were pretty much right on!!
that in a nutshell is what i am trying to do..with some specifics even! (sorry it is in metric!?.. 50mm =~ 2", 110mm =~4.3"! 13mm=~1/2") the only thing i think is really unclear is that the jig is one piece ( a "U" shape), the bit has an 8mm shank and that the router uses the flat edge at the base to ride along to keep the bit as low as possible
not entirely sure, but my guess is that this could be ok as it is, but i would like to replace the jig with something that i can setup faster/easier.. without having to make a new jig for every specific cut.. but really (as i guess i know) it is of course best to make specific jigs if i need to be doing a lot of these; the problem is that we end up doing a number of prototypes and well, need to speed things up, and it would be nice to be able to make angle adjustments on the fly.
i guess, the feed rate will have to be quite slow and/or make many passes to keep the bit from straying, or well, .. bending. we have been kicking around a couple ideas, but i think we may just give this a try first to see how much of a problem we get from deflection. if you guys have ever done anything like this, let me know!
.. i got to say, ya'll have been really great help already! great forum!