So the alignment of the re-cut came out fine. I used a slightly different jig, and placement was done all in the artwork on a 12x20 canvas. Can’t really say what caused the first go-around to come out skewed.
Next issue is getting a consistent cut through the material. The material is 1/4” (really 0.236”ish) Baltic birch plywood. Calling it proofgrade thick dradtboard cuts through about 90% of the time. I switched to a manual cut and slowed it down as well as correcting the material thickness and the success rate was no better- just more burning/char. I switched to two passes at a somewhat faster rate and still not an improvement.
In some spots it cuts fine but in others not so much. Originally I guessed that the areas where it was not cutting through were only a few thousandths shy, so I ran the whole thing through my planer figuring I could lose a little off the back and that would be easier than exacto knife work. But I ended up planing away almost 1/2 of the board and there are still areas that are not cut.
I know, I know- that’s what proofgrade material is supposed to solve. Maybe it could get offered in larger sheets for such purposes?
Meanwhile, anyone with the magic settings for 1/4” Baltic birch, please share!