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Handcut Endgrain Inlay

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Blog entry by SPalm posted 01-18-2010 06:32 AM 12755 reads 39 times favorited 22 comments Add to Favorites Watch

This is so stolen from Geoffrey Noden of the AdjustABench. He demo’ed this at the Wood Show and Karson blogged about it. I thought it was pretty cool, and since it is not on the market yet, I thought I would make my own.

Not sure what I was doing, I made what looks like a paper cutter. The arm rides between two longer sides to keep it stable and square. It is about two feet long. The cutter bar is hinged with a bolt so that it is level when it is 3/4 of an inch above the base. This lets the cutter strike while it is level. Thinking that I wanted it strong and adaptable, I used bolts for the cutter mechanism so I could adjust it for tightness.

I made custom cutters buy sawing apart small blocks with S-curves and gluing them back together with double edged razor blades between them. These blocks are 3 inches long and 2 inches tall. The blades are 1.5 inches tall. I cut mine on the bandsaw. A scrollsaw would be a better choice but I had trouble cutting these with mine. I just went with what worked. I let the blade extend about 1/8 inch from the block. A note to be careful cleaning up glue squeeze out.

Then I mounted these blocks on the end of the cutter arm.

I chose 3/4 inch for the width of the inlay because I had a router bit and some stock that wide. I did the stock prep and started crosscutting strips to use. I started at 1/8 inch, reduced it to 3/32 inch, and ended up cutting 1/16 inch strips. This takes a very sharp blade. I used a high tooth blade without much set.

I added a stop block clamp so I could do repetitive width cuts if I want to. I used a poplar block with a dado to keep the strip steady and supply a soft landing pad for the blade.

Here you can see some of the strips that I will keep for a rainy day, and some test cuts.

Here I tried some repetitive cuts in some cherry.

Steve

-- -- I'm no rocket surgeon



22 comments so far

View Karson's profile

Karson

34874 posts in 3052 days


#1 posted 01-18-2010 06:40 AM

Cool: A great start. I didn’t see how you held your cutter straight to get the repetive cuts with the same shape.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View Karson's profile

Karson

34874 posts in 3052 days


#2 posted 01-18-2010 06:40 AM

excuse me first picture.

Did the blades bend easily?

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View SPalm's profile

SPalm

4806 posts in 2534 days


#3 posted 01-18-2010 06:48 AM

Yes they did bend, especially in the beginning. That is why I ended up with 1/16 inch stock. The 3/32 was a little stout. It also greatly depends on the wood being cut. The Spanish ceder cut really clean, but the hard maple was…. hard.

I started with blades from disposable razors, because I could not find double edge blades. These were small and cheap.

The new blades with good wood choice and care works pretty well.

Steve

-- -- I'm no rocket surgeon

View a1Jim's profile

a1Jim

112079 posts in 2229 days


#4 posted 01-18-2010 06:49 AM

great start cool

-- http://artisticwoodstudio.com Custom furniture

View degoose's profile

degoose

7010 posts in 2006 days


#5 posted 01-18-2010 07:44 AM

I saw the original post by Karson… now I see this… it is as easy as I thought it would be… bl**dy marvelous..

-- Drink twice... and don't bother to cut... @ lazylarrywoodworks.com.au For lovers of all things timber...

View scrappy's profile

scrappy

3505 posts in 2082 days


#6 posted 01-18-2010 09:08 AM

Fantastic. I was hopeing to get more info after seeing what Karson had showed us. Might have to try this myself. Problem is my to-do list is allready way to long.

Thanks for the detailed info.

Scrappy

-- Scrap Wood's the best...the projects are smaller, and so is the mess!

View Eagle1's profile

Eagle1

2066 posts in 1716 days


#7 posted 01-18-2010 11:55 AM

My list is way to long also. Way (well not to long) I quess to many things I want to start doing. Just dont know what to do next.

-- Tim, Missouri ....Inside every older person is a younger person wondering what the heck happened

View bigike's profile

bigike

4031 posts in 1940 days


#8 posted 01-18-2010 02:02 PM

good job. so u stack a couple razors inbetween wood blocks with the shape cut on them to get the cutter shape?

-- Ike, Big Daddies Woodshop, http://www.icombadaniels@yahoo.com

View mtkate's profile

mtkate

2049 posts in 1977 days


#9 posted 01-18-2010 02:08 PM

You people and your jigs are so impressive…

View SPalm's profile

SPalm

4806 posts in 2534 days


#10 posted 01-18-2010 02:22 PM

Ike, No, only one razor blade installed at a time. Each razor blade has its own profile. The toggle clamp is used as a stop block. You make one cut through a new strip. Slide the left side over a little bit, and lock down the clamp. Now slide the right side to the left stop block and recut. Remove the small cut part, slide the right to the stop block, .....

Steve

-- -- I'm no rocket surgeon

View SteveMI's profile

SteveMI

852 posts in 1946 days


#11 posted 01-18-2010 03:01 PM

I would have never thought to try bending a razor blade!! These are just miniature steel rule dies.

Are you just letting the arm fall to cut or do you have to put pressure afterward to complete the cut?

Steve.

View SPalm's profile

SPalm

4806 posts in 2534 days


#12 posted 01-18-2010 03:24 PM

Hey Steve,

Exactly, they are just little dies. Pretty cool, me thinks. I tried for a while to use 1/4” copper tubing for circles, but I need to experiment more.

I have to apply a little downward pressure. It then snaps as it cuts through the piece. It greatly depends on the wood. If I have to press too hard, it will destroy the blade. It is chopping through endgrain, so it is not as hard as you might think. The example in cherry above is 1/8” thick.

Steve

-- -- I'm no rocket surgeon

View SgtSnafu's profile

SgtSnafu

957 posts in 1923 days


#13 posted 01-18-2010 05:59 PM

I love the concept – Great Idea.

Thank you for sharing

-- Scotty - aka... SgtSnafu - Randleman NC

View mgb_2x's profile

mgb_2x

167 posts in 1721 days


#14 posted 01-19-2010 01:13 AM

Wow really cool technique, could add a nice touch to some of my plain boxes.

-- "aim small miss small" m g breedlove

View calvin's profile

calvin

1 post in 1645 days


#15 posted 03-16-2010 10:39 PM

Nice job SPalm. Too bad you couldn’t support the guy that designed this thing. I met Noden in Somerset NJ and he’s a hard working guy that has all his parts made locally and assembles them himself. The retail price of this product will be less than $200.00 from what I understand, which seems pretty reasonable. Does your “copy” have repeatability when it comes time to make the same design? How accurate is it? How user friendly is it? Is it durable? I’ve always tried to support folks who work hard to come up with innovative new products. At least you gave a plug to the brains behind the product. Carry on.

Cal

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