I ran some tests this morning with a brand new EM from the same company that made the one that's throwing the big burr, and another brand (twice as expensive ). All were 1/2" dia. 1.25" LOC and 3" OL. It's the manufacturer, the results were rather startling. Not only was the burr almost non existent with the more expensive cutter but the finish was much better and it was much quieter during the cut.
I appreciate all the suggestions and advise. I guess you get what you pay for.