So, I suppose I should follow this up. That routing setup was retired. Those linear bearings are rated for millions of repetitions, and super heavy loads, but their Achilles' heel is sawdust. They kept clogging up. So we use a lot of fixed size templates, like this:



We also built a universal template. I apologize for the large file sizes, but there are some videos that show it in action:

Part 1
Part 2

Here are 2 more videos (much smaller file size) showing the use of a fixed-size template:

Part 1
Part 2

BTW, you need to have quicktime installed to play those last two videos (sure miss the edit feature on the forum).

Thanks for sharing....