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Koa Jewelry Box Inlay Process
  Here are the first laminations in forming the corner ovals. The mango has been coved out on the router table, and matching black palm pieces have been rounded on one side, glued in place, and then rough beveled on the band saw in preperation for their second, final roundover on the router table, using the set-up below.
     
  Here's a close-up of the pieces above. Next photo shows their next step.
     
  Here's how uniformity of size and shape are attained using tiny wood spring hold-ins attatched to the left side of the aluminum fence, and a plywood pusher. The mango piece is barely visible beneath the pusher. A round-over bit tilted 45 degrees creates the right profile.
     
  Here's the pentultimate clamp up of the corner pieces. The next step is the most critical; rounding both of these palm wood half-ovals into ovals to fit into the female recesses waiting for them, shown to the left, and just visible in profile on the piece in back. Those last cuts, performed in a manner similar to the one shown in the router table set-up above, are very,very sensitive, with an error of as little as 1/100th of an inch being a major problem!

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