Thanks for all of your replies. I see my problem as trying to cut into
the grain with a wood that is already prone to chip-out.

Excellent ideas. Flipping the pattern to the other side to continue to
cut with the grain is probably the easiest. I like the robosander on
my DP idea. With 50 grit on redwood, it would cut like a router bit.

Whiteside as a spiral flush cut bit but at $70, an expensive solution
and would probably still cause tearout unless a backer board was used.


Thanks again for your suggestions.