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This might just be a problem with 1/2 inch birch plywood.  I finally got the Mini secured well enough to try it - which is a story in itself.   I drilled my very first hole with my Kreg Mini and on the surface it looked fine.  But I turned the board over and the layers of laminate were separated.  It was split just like as if you had driven a nail there.   Is there any way, other than not using plywood to stop this?

 

Joe

elpasobooks@sbcglobal.net

 

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I have made several projects with 1/2 inch birch and haven't had a problem. I would suggest making sure you have the drill up to speed. Free your sawdust while drilling and make sure your collar is set at the correct depth.
I think the problem is that my plywood had very few layers and the bit just pushed the middle layer out. 
Plywood is already undersized so with 1/2" ply there is very little wiggle room between the plywood surfaces and the 3/8" bit. I use a microjig on that.

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