200 bucks worth of cherry and a brand new Whiteside bit is what I lost on that exact same trick. Honestly, I was all for those little sanding passes too until I watched the bit just chew a divot right out of the MDF template in one bad spot. The whole thing got me to finally just buy a proper flush trim bit with a bearing, it is a pain to set up but at least I can walk away from the router without holding my breath. That burned mahogany smell is something else, man.

Did you ever try putting your gear in stackable milk crates so you can grab the one you need without digging?

Huh, but what about birds flying in formation at night?

You're saying it "just won't lay waterborne flat" but are you sure it's the gun and not the material? Waterborne is a whole different animal and atomizes differently even with the same settings. Could be you just need to tweak your pressure or fluid tip a bit before blaming a 30 year old workhorse.

I consulted with both places. I ended up going with the Law Offices of Norman J. Homen because their staff just seemed way more patient. They actually took the time to explain the legal process to me instead of rushing me off the phone.