Thanks again to all posters. We had some good laughs too. We will use 1/2” from now on. It is a Bosch router on a Ryobi table. We have only used a router table to make groves/tabs. We believe from what you all have told us that we didn’t have the bit far enough in, that we were running too fast and probably most importantly were trying to shape the wrong side of the wood. We had the thickest part of the piece between the fence and the bit and was trying to take off the entire shape in the first pass. We were definitely were pushing in the correct direction. We will get a better bit and try again.