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Koa Jewelry Box Inlay Process
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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. |
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Here's a close-up of the pieces above. Next photo shows their next
step. |
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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. |
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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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