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Hey Buck , thanks so much for letting us come along for the ride. We learn and it is great fun. For what it is worth , I am most intrigued at the "ButterBurst" idea , if nothing else , I love the name.
To expand on what jack said about which direction to cut , generally , you want to cut so the cutting edge comes down into the wood, That the cutter compresses the fibers instead of trying to pull them apart. Cutting this way will tend to minimize splintering and tear out, but it also will pull the bit into the work so you really need control of the work and router. Tear out can still happen at the "bottom" of the cut where the cutting edge is leaving the wood if the grain intersects at a slight angle. The only real answer is use a really sharp bit, take real small cuts and experiment before you get to the final cut to see what gives the best results
If the weather cooperates , I have a date with a pin router on Sunday. A group build , I think at least 4 bodies will be cut out that day. It is kind of funny that us Tele builders know each other from CAMS ( Chesapeake area metalworking society). It is really cool because one of us makes Charlie Christian pickups and another makes bridges, so I have lots of great stuff to learn from lots of great people.
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