toomanyknots,
Nah, don't let anyone bring ya' down. I'm one of those folks who buck trends on a regular basis just to find out for myself WHY things happen the way they do.
The biggest way that I buck trends these days is that I build backed board bows to exacting dimensions - exacting to the point that they hold tolerances to within the thickness of a pen line. And they produce outstanding, predictable, and repeatable results... I was an architect, so I guess I come by it honestly.
The name of the game is trial and error, and the only WRONG way to do anything is just not to do anything at all!
but....... what if the wood is different densities and bending strengths along the length of the bow?
Very unlikely. We make "pyramid" bows all the time that are uniform thickness throughout the limb and have straight taper sides. Any small amount of variation in material can be corrected by slight scraping.
Back on topic, when you guys run your square stock through the router setup and get the stock in as far as you can with the drill, just unchuck your adapter parts and chuck the drill on the far end of the finished part of the shaft and pull it on through. No need to back your shaft out because the drill can't reach any closer.
Also, there is no need to make your square stock half inch. That just wastes wood. Make the square stock 3/8" and your entrance hole 33/64". You will have a 25% saving in wood.
Your placement of the cutter directly under the shaft avoids having to make an adjustment arrangement, but your cut is cross grain. Putting the router bit at the side of the shaft puts the cut in line with the grain, resulting in a smoother cut. That also allows the use of a dial indicator, making adjustments visible in thousandths of an inch.
Jim Davis