Grandpa's Box #2: Panel with Inlay

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Blog entry by gizmodyne posted 06-26-2008 07:13 AM 1434 reads 1 time favorited 12 comments Add to Favorites Watch
« Part 1: Halfway Part 2 of Grandpa's Box series Part 3: Finishing Up »

More Progress
I started the day out by planing the remaining miter keys. The trick is plane down from the corner to avoid blowing out the grain.

I picked stock for the panel lid and resawed it to around 3/8”.

Yesterday I bought a new blade for cutting the miter keys. I did not have a flat ground blade and wanted one for the miter keys. I used it for cutting the panel grooves and a little ripping. Nice so far.

I offset the groove so that I can rabbet the bottom of the panel later.

The mitering setup.

I rabbeted the panel from 1/4” stock.

I have never done inlay before. I have watched it done on t.v. so what the heck. Go for it.
Surgical instruments set out.

Etching the outline of part one. Inlay stock held with double sided tape.

Darkening the lines.

Tiny router bit. This takes concentration.

Cleaning up the lines.

Part one done.

Layout for part 2.

Picture Story…...


There were a few tiny gaps I wanted to fill. I taped off the area.

I mixed up CA glue and walnut dust to fill the voids.

Finished Inlay

Glue Up
I sanded the panel before glue up. I am getting into taped glue ups. Easy. I put spacers in to get the panel to sit correctly. I glued a drop on the middle of the ends of the panel to keep them in place and allow for a bit of expansion.

Finally, weighing down the panel so the glue drops hold.

Next up. Keys for the panel. Rabetting. Sanding. Finish.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke."

12 comments so far

View Scott Bryan's profile

Scott Bryan

27250 posts in 3792 days

#1 posted 06-26-2008 12:34 PM


This is looking good. The inlay was a wonderful insight and adds a nice touch to the box. It takes a great deal of courage to try something new like this, especially when you are under a deadline and the piece is as important as this one is. Great job.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View Bob N's profile

Bob N

131 posts in 3897 days

#2 posted 06-26-2008 01:38 PM

I have been looking for a way to do a cross inlay and your technique answers the call perfectly. Thanks for sharing this, it is going into my saved project file.

GREAT job on the box so far. Can’t wait to see it finished.

View teenagewoodworker's profile


2727 posts in 3738 days

#3 posted 06-26-2008 03:30 PM

great job on the box. from past experiences i know how hard it is to get a project done with a deadline, and put everything you’ve got into it. such as the inlay you did! great job and thanks for the post!

View Todd A. Clippinger's profile

Todd A. Clippinger

8901 posts in 4069 days

#4 posted 06-26-2008 03:47 PM

Thanks for sharing during such a personal time.

-- Todd A. Clippinger, Montana,

View Douglas Bordner's profile

Douglas Bordner

4023 posts in 4033 days

#5 posted 06-26-2008 06:16 PM

Please accept my condolences for the loss of your family member. It’s a great honor to be asked to make his urn, and you have done your service well. The box looks great, with your usual tight workmanship and attention to detail both in the project and the subsequent blog.

Cutting away the ground for your inlay with that big ole router looked to be a hair-raiser. Glad it came out beautifully.

-- "Bordnerizing" perfectly good lumber for over a decade.

View Chris 's profile


1879 posts in 3961 days

#6 posted 06-26-2008 06:24 PM

Excellent work, I appreciate your blogging this journey for us.

-- "Everything that is great and inspiring is created by the individual who labors in freedom" -- Albert Einstein

View Dorje's profile


1763 posts in 3967 days

#7 posted 06-27-2008 12:00 AM

Looking good John -

What did you use to space the panel? I’ve used “spaceballs” and rubber tubing before, and am always curious about what others use…

-- Dorje (pronounced "door-jay"), Seattle, WA

View Betsy's profile


3391 posts in 3866 days

#8 posted 06-27-2008 01:25 AM

I think you are doing a great job. Very brave of you to try inlay on such an important project.

-- "Our past judges our present." JFK - 1962; American Heritage Magazine

View gizmodyne's profile


1777 posts in 4060 days

#9 posted 06-27-2008 04:58 AM

Thanks for the comments, thoughts, support.

Douglas. I was sweating doing the inlay. Sweating!

Dorje- I just centered it by eye, put a little glue drop on the ends of the panel bottom, and weighed it down.

-- -John "Do I have to keep typing a smiley? Just assume it's a joke."

View Blake's profile


3443 posts in 3844 days

#10 posted 06-27-2008 05:29 AM

You are brave on the inlay stuff. I have yet to try something like that. I’m sorry to hear about your loss, John. What your doing is the perfect way to honor him. Keep up the good work and thanks for taking the time to blog the progress, we all like to see it.

-- Happy woodworking!

View Dorje's profile


1763 posts in 3967 days

#11 posted 06-27-2008 08:46 AM

Oh, I thought I read that you put spacers in, which you did state, but now I think I understand that you must have meant that you did so from the outside…to align the panel for the glue up.

Looks like you’ll be ready for Saturday…very cool that you could put this together for the family.

-- Dorje (pronounced "door-jay"), Seattle, WA

View Mario's profile


902 posts in 4021 days

#12 posted 06-27-2008 01:48 PM

Thank you for the level of detail that you include in your posts. It helps us beginers a great deal.

-- Hope Never fails

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