Make the spade template
Start at the spade. After transferring the template
pattern on to your template stock, bore the top
lobes with a^1 ⁄ 2 "-dia. Forstner bit. Complete the
cutout with a jigsaw outfitted with a fresh finish-
cutting (10-12-tpi) blade. Leave the pencil line.Finish with a file. Use a mill file and a draw-filing
technique to create smooth template surfaces. Keep
the file parallel to the bench as you shave to the line.The ½ × 3 × 35" template matches the width of the
stiles, and provides some extra length for clamping.
After completing the cutout, attach a stop block to
the rear face so that the inlay starts about 6" from the
stile’s top end. The template is used for routing the
recess and the inlay, so take your time and get it right.
Create an inlay detail
with a special bit kit
1 square=^1 ⁄ 2 "
Enlarge 200%This inlay kit will make your router even
more versatile. It’s designed to work with a
template, so your first task is to make one,
as shown at left. When it’s time to rout the
recess and the inlay, don’t rush your cuts
with the tiny bit. Routing the inlay is more
difficult than routing the recess, because
there’s no margin for error. If the bushing
veers away from the template edge, your
inlay will be ruined. To avoid hang-ups, try
lubricating the base of your plunge router
with a product like Bostik Glidecote (see
Buyer’s Guide, p. 69). A few practice runs
(with the bit retracted) can also also help.
The most difficult times to control the
router are when the bit enters and leaves
the wood. I find that it’s easier to achieve
a steady start when bushing is “trapped”
against a corner or the top-most point
of the spade. When you’ve worked your
way around the template, raise the bit and
turn off the router. It’s smart to prepare
some extra inlay stock in case you need
a second chance to rout a perfect pass.
TIP: When you buy an inlay set like
the one shown here, it’s smart to order an
extra ⅛" downcut bit, because this tiny
cutter is more fragile than larger bits.Template(^1) ⁄ 2 " Forstner bit
Template
Pattern
Template guide bushing 5
⁄ 16 " O.D.
Downcut bit
(^1) ⁄ 8 " dia.
Inlay guide bushing
(^9) ⁄ 16 " O.D.
Centering pin