I agree something like that is happening.
You are beyond my level of expertise on this topic.
Most routes across state boundaries worked fine.
First problem I found was at:
30.5783 latitiude  (north)
-87.4607 longitude (west)

Problem went away when I eliminated the merge step
by using usa-south-latest.pbf that had very close the
same states I wanted anyway.

So little time and so much to learn.
Kevin



On Saturday, November 24, 2018 at 6:43:06 AM UTC-5, bughunter wrote:
>
> If you are having difficulty creating maps that route you across state 
> boundaries, it may be because your filtering process is removing the 
> essential tag that makes this possible.
>
> The end node of one line segment in one state must be tagged with 
> mkgmap:on-boundary =1. A corresponding node at the same GPS coordinate in 
> the next state must also be tagged with mkgmap:on-boundary = 1. That's the 
> magic that makes interstate routing possible. The nodes can be in different 
> map files. so you can simply add additional states that you want to route 
> into.
>
> Check your post-filtering boundary crossings to make sure these tags are 
> present.
>

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