Trying to cut 40mm maple with anything from Black & Decker will be as fruitful as throwing spitballs at an elephant. All you'll get is dulled and broken blades for your efforts. The router had better be 3 horsepower with 1/2" shaft bits or they'll suffer the same result. I'd take it to your local lumberyard that has a full woodworking shop, or a profesional cabinet maker, and have them do the cutting with professional grade tools. Routing that maple even with a 3 horse router could take hours at 1/32 inch per pass; a pro will do it in 15 minutes with a Bridgeport vertical shaper. What you have to pay to do the job will be well worth it.
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