I think your absolutely right Mark. The mistake I made was cutting the clay model before I poured a master. At the time I was thinking if I make the cut then I can build a mold for each piece therefore all the baits would be exactly the same. Then I wouldn't need to cut the joint in each bait. RTV cost also played a role at $32 per pound after shipping. Looking back I should have molded a master first, made the cut or cuts, and then poured a production mold. I suppose I could hot glue the master back together, fill in the cut with clay, and make another mold. Live and learn I guess...
I sort of built this thing on a spur of the moment idea. And I had some old plex glass hanging around I used for a bill until the lexan arrives. I also had some circuit board bills too. I didn't use them at first because I thought with the weight of the bait smacking things from time to time it may not be durable enough. But after installing one on the rat it swims great. I think the circuit bill is a better option. It cuts through the water better and has enough flexability to give a little vibration to the bait. I tried to break one and they are pretty tough........