Tom, I make emblems that have lettering and designs similar to the lettering on your fuel cap. The "tails" I experience are usually from wayward entry and/or exit settings of the cutter. So much so that a lot of the time I just slow the feed rate way down and do not use a ramp (helix, 3D path, etc) entry at all - just plunge at each level. For some of the fine detail I am using a high-speed spindle with end-mills in the neighborhood of 0.010", so easy entry is important.
USMC emblem is about 2.25" diameter
As a side note, I've managed to figure out ways to powder coat the designs instead of paint. Makes for a very durable product. Finish is usually either satin, burnished or polished to a chrome-like surface.
I think you hit on it. I had "tangent with a .125" radius" set as my leadout setting. I'll play with it in the morning.
Couldn't open your attachment. I get a forum failure error.
Tom S.