Almost in the returns pile. But after a bit of troubleshooting, I found that the bit that created the notch in the face was set too deep in the chuck, causing my material to slide a little on the chuck, but enough to allow the material to "ruin". Took the cutter out of the chuck and PROBLEM SOLVED. I completed the cut in 2 passes. Less stress and a clean cut. First I cut out a piece with an internal thread, which turned out to be a 1/4 spigot. Then I set another bit to the approximate height. Using scrap material I trimmed the pattern to a perfect fit before using it on my finishing stock. I used a 2-1/2" layer glued to form a 1" shelf stock. The front was 3/4" x 1 1/2" solid wood. This allowed 1/2 inch overhang.
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