: If you really wanted to do it this way what I'd suggest is to take
: all of the figuring out of the equation and just use a flush
: trim bit. As long as you save both halves of your
: "puzzle" you just flush-trim to each half, and it will
: fit the same as it did on the original patterns.

I thought about using a flush-trim bit and two patterns. You'll have a gap that is the width of whatever saw blade you used to cut the pieces. It may or may not be enough to matter.. Another issue: you'll never be able to sand the pattern either. You have ONE shot of cutting the pattern out correctly. The collars system does away with these issues. One pattern that can be smoothed, reshaped as needed. Cut one side with the big collar. Cut the other side with the other. Done.

Um, Mike? You realize this all academic, don't you?! I hardly scarf plywood to begin with and when I do I just sand them with my belt sander. I can sand tight scarf in 4mm plywood in less than a minute. I NEVER see myself doing any puzzle-type joints!! :)

Later,
Dan