[labdude]

Undercuts can get ugly. I know what you mean.
In those Tori cases, extreme or not. I always have wire overlap. Even on a modle with no tori.
On a lower, it's usually the rest I extend. It goes anterior all the way under the labial bow by about 3 or 4 mm. Sometimes I do it with the clasp involved. Makes a lower a little stronger. Done carfully it doesn't increase thickness of acrylic. It also gives you a depth guide for lay on acrylic.
On uppere I don't have such overlap of wires. I do loop the ends of all wires that are in acrylic. They need that, or at least a few zig zag bends. Wires will twist in acrylic and work loose otherwise.
If you place acrylic starting on one side of an upper, and work to the other side, rather than doing halves. Your acrylic might come out less thick and require less grinding time.
I find it's not so much the use of extra acrylic that causes a cost problem, it's having to spend extra time grinding excessive acrylic thickness.
Linda will have to record me working, still, time is the issue. I wish I could do it right now, it just might help a lot of younger labs. Movies of everything, from a ball clasp to a crozat.