Unmasking a burn-free edge
Here's the method I use when template routing. After cutting close to the traced template line with the bandsaw, I apply two or three layers of masking tape to the edge of the template before affixing it to the workpiece. After using a pattern bit to make an initial pass, I remove the tape and make a final shallow pass with the router, eliminating any burn marks.
—Everette Blair, Seminole, Fla.