Ben,
Hit the nail on the head, Thanks I am thinking I did the same thing, with the tape issue. I will try to do two passes equaling .1175" so it is close to the .118" thickness, if you think that would be best.
I was using this bit as well: MLCS the 5141 carbide bit & does well so far.
I just received some Onsrud 63-710 made for cutting plastics here: Zoro cheapest I have found with free shipping. It also has a larger chip extractor.
What speed rate do you suggest for two passes in the material?
Sincerely,
Matthew