[scook]

Hey PJ - it kills me for a guy to have a tool he wants to use but can’t. Are you sure it only takes 1/4” shank bits - there’s often an adapter that slips into the 1/2” chuck which can be removed. If not, watch for a sale on bits and buy one, probably a 1/4” radius round over and have some fun easing the edges on projects you make.

Not hijacking the thread - nice work on the starboard pieces. To avoid the little ridge, I always keep a scrap of material to test the cut. Another thing that REALLY improved my edge routing work was to get a router lift - made a router table out of the extension on my table saw. It makes managing the material much easier and more consistent for this kind of work.

You’re going the right direction - several years ago, I replaced some of my wood with new wood - I wish I’d done what you’re doing.

Looking forward to pictures of the completed project.