?? pocketing letters

I am making a sign with pocketed letters
Made a pocketing tool path using .50 end mill bit and then .25 end mill bit.
When I run the .25 end mill bit it cleans up all around the letters, but does not seem to go all the way down in the pocket to where the .50 end mill bit cut at
?? is there a step I'm missing in my toolpath or should I be using a different bit Attachment 26643
I can't seem to upload the file for the clearing toolpath as it says it's too big to upload to forum
any help will be appreciated
thanks

Attachment 26644 here is a photo

This is most likely one of the following:

1) 1/2" & 1/4" tools were Zzeroed at a different XY position from one another.

2) Material is not adequately held down, has cupped after cutting first toolpath or is warped and has deflected under the pressure of the tool.

Most likely #1, but could be a combo of both.

Make sure you hold the plate down keeping your fingers out of the way as you run C2 to make sure it is flat against the work.

-B

did you change the bit diameter in you set up