Inlay gaps - any ideas?

Geometry matches up, so files ought to be good.

On concern is you’re cutting a slot over 3/4" inch deep w/ a #102:

It would be better to use a more rigid tool and to add geometry and cut as a pocket down to tab depth or the penultimate pass:

A further improvement would be to leave a roughing clearance and make the last a finishing pass.

And if you haven’t, yes, you should calibrate:

That said, why not do a V inlay?

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