I routed exactly 1/16", and the textured plate looks like it is still "puffing out" a little.
Here's a fast little router tip to adjust your cutting depth to EXACTLY the thickness of the material.
-Put the mounting plate on a flat table.
-Put your router face on the mounting plate but have the bit hanging off the edge of the mounting plate.
-Lower the bit until it hits the table. That's it. Your depth is set.
Now when you cut your countersink for the mounting plate the depth will be PERFECT.
Yes, much better way.
My plain, unpainted, zinc mounting plate is exactly 1/16", and fits the routed hole prefectly. I think I measured like you discribed with the zinc plate and assumed it would be fine with the textured plate.
BTW, if I do it again, I'd use a plain zinc plate, route the correct way as you discribed, and cover the cp with a printed vinyl sheet (thus no need to spend $1 more for the textured plate).