Tape, then resaw. Tape over the routed outline to
prevent damage, and set the bandsaw fence for a
(^1) ⁄ 4 "-thick cut. Run the taped side of the workpiece
against the fence to cut each inlay free.
Practice first. With the bit retracted, make a few
clockwise practice passes around the template, so you’ll
be sure to keep the bushing in constant contact with the
template. Rout the inlay in a single continuous pass.
Install the inlay. Hand-sand a
small chamfer along the inlay’s
back edges to ease the fit. Apply
glue to the recess, then tap the
inlay home with a rubber mallet.
Use a clamp if you need extra
pressure, but place waxed paper
over the inlay before clamping a
caul over its surface. After the
glue dries, sand the surfaces
flush with 120-grit sandpaper,
then give the stiles and rails a
final sanding with 150 grit.
Inlay stock
Template
Rout the recess Rout the inlays
Stile
Stop
Template
Slow and steady. Adjust cutting
depth to^3 ⁄ 16 ". Run the bushing
clockwise against the template to
cut the perimeter of the recess, using
a slow feed rate. Then vacuum out the
chips and rout away the rest of the waste.
(^3) ⁄ 16 " deep
recess
Downcut bit 1
⁄ 8 " dia.
Ring nut
Router baseplate
Inlay
Workpiece(to create inlay)
Cut inlay free after routing its perimeter.
Workpiece (to receive inlay)
Template guide bushing 5
⁄ 16 " O.D.
Recess
(^9) ⁄ 16 " O.D. inlay guide
bushing establishes
offset to create recess.
(^5) ⁄ 16 " O.D. template
guide bushing follows
template to cut inlay.
Template
Oct/Nov 2019 | woodcraftmagazine.com 27