Thursday, March 23, 2017

A Simple Diamond Shaped Inlay Using a Hand Router

Inlay Without Power Tools

I am currently putting the finishing touches on a metamorphic chair. This chair converts from a chair to a set of 4 steps. Each step has a diamond-shaped inlay which was fairly simple to put in place. All that is needed is:

  • Blue tape
  • Sharp knife
  • Chisel (optional)
  • Router plane preferably with a spear point bit
  • Glue 
  • Sandpaper

The black corners are to be removed.

The taped side is actually the show side

Chisel cuts made over a scrap piece of wood to cut to shape

The inlay is placed tape side up. Label the piece, if needed, so that the orientation stays the same

Two pieces of blue tape hold the inlay in place.
 Ensure that it does not wiggle.

The first few knife passes are with a feather touch.

Progressively stronger force is used. but always fairly light. Ensure that the knife cuts are deeper than the thickness of the inlay.

After knife cuts are made along the edges without tape,
 switch position of the tape to the opposite sides.

Router plane (Veritas model) 
Four minute video detailing the routing out process. 

Test fit the piece


Clamps. Place waxed paper under cual.

Card scraper to remove tape from center outwards. This avoids catching the protruding edge of the inlay

150 and 220 grit sandpaper

Routing out mortises for hinges could use a similar technique.

Friday, March 17, 2017

A Tenon Using Training Wheels

Just a short post to show an accurate way to cut tenons using two unique jigs.

Warning: Hand saw purists will cringe.

To cut the tenon cheeks, I used my modified Stanley 55 "saw plane" or kerfing plane, followed by the  magnetized miter jack to guide a saw for the shoulders. The older posts will provide much more detail on the two jigs.

Once the Stanley 55 plane's fence is set for the first cheek, the remainder of similar thickness cheek cuts will not need any further setup of the plane.

Saw blade is fashioned with a couple of holes which fit precisely into the two rods.

Fence adjusted to set the saw at the correct distance

Hot off the presses. Will need some clean up at the intersection of the shoulder and cheek.