So The Finishing Lady had a thought and I tried it tonight. She wondered if a flat tipped Vee bit would solve the fuzz problem.
So we purchased this one:
The results were quite successful!
This was done with a single pass. During the process, mucho fuzzo, but as the process continued, the endmill or repeated passes of the flat vee cleaned those fuzzies right away.
For the engineers and rocket scientists in the crowd, I’m sure you immediately realized that geometry of the flat vee versus a full vee created a different set of problems, especially with narrow “woodgrain” look causing a thinner remaining area. Fortunately it wasn’t “TOO” thin according to Cathy.
The other change is the “less sharp” inner corners of the letters. But again, The Finishing Lady said that that is totally fine (and she might like it better).
For now, though, until I find a cleaner carving HDU, I finally have an acceptable work around with which I don’t have to run a vee carve three times while cleaning the fuzzies off with a nail in between two of the carves.