Here is my process for cutting the inlay shown on Glen Huey’s mirror frame. First I used a 2-1/8” forstner bit to cut a hole for the template. The template is made from 1/4” mdf core plywood, and a couple 2” wide strips of mdf on the underside.
The underside of the jig is shown here. The mdf strips trap the 3-1/2” workpiece, and center the hole. My walnut stock was less than 3-1/2” wide, so I wedged it in place.
Here is the jig and the router setup. I use a bushing guide which allows me to cut both the recess and the inlay with the same pattern.
Several walnut plugs are routed. Then they are cut free at the bandsaw. Tape holds them in place untill I am ready to remove them.
Here the plug is glued and tapped in place. I am always amazed how good the fit is with this bushing guide.
Plug sanded flush.
Then it’s just a matter of routing the grooves with a router and edge guide.
Inlay complete. The strips sit proud of the face by 1/8” and have nice eased edges.
See the finished project here: http://lumberjocks.com/projects/72234
-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush