Dauds

Can't quite tell from the pic... Is that the 'pointer' protruding near the bottom of your sled that follows your guide block? If so, I have one small suggestion: I'd make the pointer the same width as your chisel. That way, if you happen to turn your sled so that it's no longer perpendicular to your template, you won't dig the corner of the chisel into your work piece and veer from your guide design. Understood, that might be more complicated than it sounds (if you ever want to use a different chisel thus requiring a new 'pointer').

I agree with fshng2's suggestion. However, did you give any consideration to using super glue? While it's not my personal preferred method, I think it would be thin enough to soak into the voids and possibly eliminate the slight looseness you mentioned. However, that might 'lock' you into sealing the whole bait with super glue, though. I only say that as I'm not a fan of 'mixing' sealer types here and there on a bait (again, personal preference).

I'm quite impressed with the cleanliness (not sure how else to word it) of your through wire construction. .062 stainless, eh? Thinking about that makes my hands hurt.

I typically leave my compressor at around 60 PSI. Then, I've got an in-line regulator to adjust the pressure, as needed, at the airbrush.

It can seem daunting at the start up of a business. There are set costs which can't be avoided (incorporation, copyright, etc.), but you'd be surprised where you can save some money if you network correctly and find the right people. It's amazing how many are willing to barter for their services. A big bill from a lawyer preparing your paperwork is tough to swallow before you've begun making any money. But, if you can find one willing to do the same work for a custom rod and a handful of baits... Lawyer, graphic artist, web developer, even our insurance guy, we get significant discounts in exchange for some of our gear.

Ha! Oh, I could almost see it... Lawyer: "Well, your Honor, my client had dropped the lure in his live well. It was so realistic looking, he cleaned, battered, fried, and consumed it along with the other fish he had caught that day..."

I'm a new member with zero reputation here, so I'm a bit reluctant to jump in with slightly off-topic advice. That said, I keep re-reading this post, and the don't "be a statistic" comments hit close to home. Payment issues aside (been burned by that myself), you may find yourself with a liability problem. DaleSW mentioned two that have responded here are business owners (I know not which two members). I absolutely don't want to speak for anyone else, and please believe I'm not trying to be a 'downer' or dissuade anyone from the 'starting a business' concept, just be careful. It's a big, scary jump from selling as a hobbyist to friends and acquaintances to starting a company and selling to strangers. If a buddy somehow hurts himself with one of your baits, you can trust it'll just be a funny story. If the same thing happens to someone you don't know, you could face legal action. Without the proper insurance for your company, it can hurt. Some people out there will take any opportunity to make some easy money. I suppose that's another reason I avoid people and just go fishing.

I agree with your theory with the oversize lips. I've been able to get some nice slow speed wobble (albeit on a bit larger lures) with a circular lip. Typically, I'll turn a lexan lip with a diameter about twice the width of the (average) lure body. Being circular, the lip doesn't protrude too far forward, but further out the sides than I usually see. I tend to put them in at 45 degrees. Shallower or steeper angles don't seem to offer significantly different action. Also, when jerked instead of trolling, you can get some great wounded fish action.