I am using Alphacam 2014R2 essentials router. I have to make a sign for a guy at work that is retiring. They want it to be cut with a 90 degree V-bit .500" deep. The problem is the that the sign is 75"x30"x1" made out of some pretty expensive wood. There will only be one shot to cut it so it has to be right the first time. With the 45 degree bit it will cut the inside of all the letters with the 3d engrave but then it leaves sections in the middle of the letters that are not cut. They want those sections to have a flat bottom. This is my first time doing any 3d engraving or lettering at all. Everything else I cut is pretty basic. I have tried pocketing with the V-bit and it doesn't work. Nor does pocketing with a 1/8" end mill leaving .500" material for the V-bit. It cuts off parts where the V-bit should be cutting.
Attached is a DXF of what I am trying to cut. Any ideas on how to program this sign?
The end mills I have are 1/2, 3/8, 1/4, 3/16, 1/8 all 2 flute flat bottom and a 90 degree Vbit
Material top 1"
Final depth .500"