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I've been happy w/ 13k rpm, 900mm/min and ~8mm per peck. Slow Z and excessive pecking generate too much heat. That $10+ per bit price is insane, metric is typically a lot cheaper if you're patient,...

Loose machine and/or bit deflection from cutting too deep and/or too fast. If your CAM has any bidirectional cut options you'll see sidewall steps from the alternating deflection. Climb cutting...

I think I'd trust Elaire more than the eBay listings I saw, they're also a bit cheaper - Elaire Corporation -Router Collets

They're 5.66A (parallel) which sounds really high (for 57x84 400oz) and would seem to rule out a lot of drivers, e.g. DM556.

Solid state relays are a better choice; better isolation/less EMI and a simple two-wire low draw (25ma max, typ <10) trigger (e.g....

What you're showing is tearout and it can happen anytime the bit cuts diagonally across the grain. With plywood circles, each ply has two (opposing) quarters most likely to show tearout. The pictured...