Round Wood Inlay

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Forum topic by docspencer posted 08-09-2016 03:15 PM 660 views 0 times favorited 7 replies Add to Favorites Watch
View docspencer's profile


374 posts in 2145 days

08-09-2016 03:15 PM

This may not be the right forum. If its not, please let me know.

Here goes: My wife wants a circular inlay in a bench I’m building. I plan to use a forstner bit to cut the round hole and a hole saw to cut the round piece of wood to fit snugly in that hole. Do any of you know what sizes of each cutter I need to pull this off. I’ve tried to look up the inside dimensions of hole saws but to no avail. Help!

7 replies so far

View MadMark's profile


979 posts in 1652 days

#1 posted 08-09-2016 03:25 PM

Your inlay will have a hole in the center if you user a piloted hole saw. The wall thickness is typically 1/16”+- so 1/8” smaller dia should work. However your edges may be very rough.


-- Madmark -

View HerbC's profile


1790 posts in 3059 days

#2 posted 08-09-2016 03:55 PM

I agree with Mark that the hole saw will leave a very rough edge on the inlay piece, even more likely to be problematic if you remove the pilot bit.

Maybe Paul (LumberJock Shipwright) can provide a better method since he is a true expert in veneering and inlay…

Good Luck and

Be Careful!


-- Herb, Florida - Here's why I close most messages with "Be Careful!"

View Gerald Thompson's profile

Gerald Thompson

1118 posts in 2434 days

#3 posted 08-09-2016 10:09 PM

I do not know how thick the inlay is but I have used Whiteside’s router inlay kit to inlay bow ties and other inlays that were as thin as 1/16’’.

-- Jerry

View MrUnix's profile


7042 posts in 2398 days

#4 posted 08-09-2016 10:14 PM

I’m with Gerald – use a router with templates/bushings to get a virtually perfect fit.


-- Brad in FL - In Dog I trust... everything else is questionable

View shipwright's profile


8165 posts in 2997 days

#5 posted 08-10-2016 04:10 AM

+1 on the inlay bushing set. Doesn’t have to be an expensive one. It will give you a perfect fit.
All the inlays in these projects were done with that kind of set. I think mine cost about $15.

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View pintodeluxe's profile


5798 posts in 3013 days

#6 posted 08-10-2016 05:07 PM

1+ inlay bushing set for the router. Use a large forstner bit to make a pattern of the hole you want to use (or buy a plexiglass template). The inlay kit accounts for the bit diameter by using a removable bushing. As long as you center your router baseplate first, you will have a perfect fit. It is one of a select few woodworking techniques that feels like magic.

I use the Whiteside inlay bushing kit.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

View TMGStudioFurniture's profile


55 posts in 1018 days

#7 posted 08-10-2016 05:47 PM

You can also get a router inlay kit at Harbor Freight.

You can make your own template from a piece of MDF.


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