So, I thought I had it all figured out. If I want consistency from build to build, I will abandon cutting out the bodies with the bandsaw and go with a router table and templates. I ran to Northern tool and bought a nice 2 inch flush router bit, then to Harbor Freight to get their little router table/router combo (1 3/4 hp). I used the bit first with a handheld 2 hp router and it worked great, cuts nice and cleanly. When I went to use the combo set up, all hell broke loose. No matter which way I fed it from, it started bucking and trying to rip it out of my hand! Chipping and breaking the mahagony in the process. I took a break to think things through.... Maybe I'n feeding it in too fast.... maybe I need to hold on tighter. So back out I went for another try. Fed the wood nice and smoothly. It went about half of an inch and it ripped it out of my hand and gouged a hole in my palm in the process! WTF?? Why would this be different than using a hand held router? Shouldn't it be MORE stable? I like the concept of templates, but right now I'm almost scared of the damn thing! I have plenty of experience with power tools, just not a router table. Any suggestions?