In your article you touched briefly on a subject to plagues me every time I try to use a template. Recently I routed a base plate for a cabinet. The plate consisted of a large arc with small radii ( 1/2" radius) at the ends of the arc. To route the edge, I used a 1/2" diameter 1" long flush cut router bit. One end came out perfectly, but when routing the other radius the router bit always grabbed and split the part. It didn't seem to make any difference which way I moved the router i.e. from the large arc into the radius or the opposite direction into the radius first. I should also point out that I was only removing from 1/16" to 1/8" (closer to 1/16"). I had used my band saw to cut close to the pattern line. The surface was somewhat ragged because the band saw won't cut that tight a radius. I believe my problem is referred to as "climb routing".
My question of course is how do I avoid the router bit grabbing and splitting the part. And, of course there is the safety issue when the part is thrown half way across the shop.