And this was my response: “Hey Don. Glad you found us! Welcome. So what brand bit are you using? Obviously, using a top quality bit is the first step to great results. The second would be to take lighter passes. Don’t bring the bit all the way up. It will take a little longer, but try taking 3-4 passes, raising the bit a little each time. Obviously that’s not an efficient solution, but its much better than losing a whole chair arm because of tear out. Also, you could relieve the sharp corners with a rasp before routing which can sometimes relive tear out. But honestly, the incremental passes is probably your best bet. Whenever I am dealing with a tear out prone wood, that’s exactly what I do. Hope that helps.”

In a follow up e-mail Don writes: “Marc, I tried your suggestion about taking lighter passes and IT WORKED. I take 3 passes and after about 30 or 40 pieces I only lost 4 due to tear-out Thanks so much. You saved me tons of wood not to mention money. Thanks again!”