Tale of the Eagle Claro Walnut cutout

[muckem]

This was a fun project. at 1.25 inches thick the test patterns and cuts on Redwood broke from small pieces breaking loose at the end.

we solved this by making the profile cut to .06 and then flipping the piece and planning the .06 away with a 1.5 endmill carbide insert bit

[traindriver]

You can also try playing around with adding tabs to the tool path. I have had a few projects that I thought might be delicate to profile, and tried adding .040 thick tabs in places that would be easy to get to to cut with a utility knife and sand. It has worked well for me so far.