I have been thinking about this for a while now. I bought an inlay kit and have used it to do inserting with it , but you have to start with an outline pattern for the router bushing to follow to make the Object and make the Shaped hole for it. But what if you already have an object and you want to make a hole for it to fit exactly into. I finally figured out what I need to do that.
My object is another Corian Alien. It has all convex curves and no radius is smaller than 1/2” so this will work.
I started by mounting the object on a board that will be my outer template. I tried double faced tape and I did not trust it so I just glued the object to the wood with Tight Bond. Then I cut around it with the router and at this point you cannot vary from that edge at all or you will get gaps. I only went down about 3/16” deep.
I had a 1/4” straight router bit and a 1/2” bushing. in the router.
Then I cut the center out on the scroll saw leaving a little bit of the routed edge
and I cut it to shape all the way through with a router bit with a bearing on the end for tracing.
Then I changed the router bushing to 1” I had to make this one because the set I have only goes to 3/4”
I screwed the pattern to the board in which I want to insert the object
and I routed the pattern around it 3/16” deep
I cut out the center and routed it through as before
And the object is a press fit with absolutely no gaps any where
Now I have a way to drop any shape within reason into another surface.
-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!