: Hi Pete,

: Have you thought about setting a scroll saw at a small angle 2-5
: degrees and cutting the shapes going counter clockwise. The
: inner part will recess without falling through, essentially
: disappearing the kerf. Outer piece can be rounded or chamfered
: and reassembled. Hopefully this makes sense.

: If the router is the choice then there is a way of pivoting your
: work off of a pin that is close to the small cutting bit that
: will allow more control, though I would discourage attempting
: this without the full information of bit speeds, direction of
: cut, etc.. Wish I could find the reference on this. Someone else
: may have more knowledge for this method.

: Best,

: Reg

Scroll saw would indeed make this much easier and much easier to control. I keep forgetting about it as I just bought my first one, even though I used it like 10 times today ;)

Bill H.