We are now ready to begin sawing out our components. By hot gluing the two boards together this allows us to cut two identical pieces of each part so that they will fit properly.
Note that I am only sawing out the interior shapes of the cross at this point. This will allow me to have better control when re-gluing. Here the vertical piece has been cut out. Keep in mind that you must get the best cut possible. Be sure your blade is narrow enough that it can saw the curves without backing up to adjust the blade direction. Otherwise you won’t get a good fit when you glue the contrasting boards together again.
Now I have cut out the horizontal piece. Save your waste pieces as they will be important when you get ready for gluing.
I then separated the two woods that had been tacked together with hot melt glue
I then inverted these pieces so that when I re-glue I will have pieces with the contrasting wood in them.
Keep in mind that by losing even a bandsaw blade width of wood the pieces may no longer fit perfectly. You will have to use your judgment and make slight adjustments by sanding or with a sharp chisel to get the best fit possible. I would recommend a dry fit of the part before applying glue.
This final photo shows the vertical cross section being glued and clamped. I forgot to take a pix when it was completely clamped so don’t worry about the gaps. I decided to wait until that dried before fitting and gluing the smaller horizontal piece. That is it for this stage. Note that I have used the waste pieces as a way to more easily glue the curved shapes back together. Be sure to not put glue on those surfaces. After the glue dries we will unclamp and repeat the fitting and gluing of the smaller piece.
-- Kevin, Blue Springs, MO