Inlay troubles

Hello everyone. I have been viewing the forum for a long time but this is my first post. I don’t have an xcarve but I have been using easel with the cnc that I have. Anyway I have seen all of the videos on making inlays with the app and have read several posts here about it. I just cannot seem to get it to work. I am using a 1/16th inch bit and I have measured it to verify everything. Well every time I cut an inlay the male is too big. It is even visible to the eye that it is going to be too large and I have used tolerances all the way up to 0.009. I am up to about 9 tests so far. I am trying to inlay some walnut letters into a hard maple cutting board, but I cant even get my tests to work. If anyone has any suggestions it would be greatly appreciated.
Thank you!

Check whats going on in this thread and see if any of it applies.

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Thank you! I think I am going to try cutting the inlay first and then adjusting the pocket like some suggested by slightly changing the bit size.