OK...The Mistake was...I took the theoretical 6'th version from this computer, transferred to control computer,jigged up the actual piece, and with that set up made all the actual cuts shown in the previous pics to get a lowest point on the cut to leave .22".
The problem was I was going by the Material setup;
And NEVER checked the actual toolpath depth
I had swapped to Z-Zeroing off spoilboard, had taken off .25" waste, and was flying by the seat of my pants to get cutting as soon as possible....WRONG!!
Material set-up was taking into account ALL the .stl depth that was on my material...NOT the depth only in my vector boundary:(
Lowest point I only noticed on the finish cut was .42"!! (Shows how observant I am while doing other stuff besides cutting
Changed Model Height to Material Thickness height Max, and toolpath preview NOW showed lowest point as .20" Yeah!
SOoo, cut the roughing toolpath AGAIN with the 1mm TBN at 10% stepover...with my Z-Zero cheated up .04" as the allowance.
Funny...Peak height was STILL set at top of material, so remained uncut....while as the elevations went down, it got closer to the total .22" cut depth...was interesting to watch
Cheated Z-Zero down .025" after that, and ran the 1mmTBN on a 5% stepover, so that final toolpath for the .25mmTBN was only cutting .015...and with heatgun my Linseed/Beeswax mix penetrates that far. BUT noticed the skin breakdown.
CHEATED bedrest rules by 7 minutes on Tuesday morning, and managed to get Maple slathered and machine ready, and started cut at 7:30am
Machine is only 50' from bed, and with shop door open...easy to listen for anything funky...and smoke alarm was near machine and fire extinguisher was 10' from machine.
1.6 million lines of code..and DID manage to levitate into wheelchair a couple time when cut paused to load more code(3 times), and checked cut for 2-3 minutes every other hour(10 hours)
REALLY not much different than the first pics(except lowest depth went down .22").
VERY slightly exaggerated things like the Saddle Trail, but unless you really know the Mountain, it still looks great!
Heartwood tree line went Up a hair.
What with all the time spent jigged down, and the changes in temp and humidity in between....Kind of amazing the actual peak, plus the 7' Cairn on top people have been adding rocks to for generations to make the Peak EXACTLY one mile high, is still attached to the Maple!
Cut out will leave vertical walls:(
THINKING of running a profile toolpath with the .25mm TBN with a 5+degree angle BEFORE the .25"Downcut bit cutout first. Maybe trick the eye a hair, and not such a harsh transition?
Got a couple more days to think about it.