Huh? The first post answers your question exactly.
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Using the larger templates it is possible to rout alternative butterfly shapes simply by using alternative template guides and cutters to rout the recess and produce the insert. This was the reason for asking what template guides you had for your router. I know of at least two sets of combinations suitable to produce the butterfly. Each combination will produce a different size but once a combination has been chosen you can produce the same shape over and over again.
Tom, he's not asking how template guides work.
He's asking why it worked before and doesn't any more with a new bit of the same size.
That's what's said before :?
This could also be the problem The template may have moved