Buffalo Box #4: Beginning the intarsia

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Blog entry by wdkits1 posted 11-30-2009 04:33 PM 2464 reads 2 times favorited 6 comments Add to Favorites Watch
« Part 3: The Pattern Part 4 of Buffalo Box series Part 5: More Intarsia tips and tricks »

I will begin this stage of the intarsia process by resawing the wood that will become the background for the box lid. I am using Lacewood that will be bookmatched cut to 3/16”

After the resawing is done I have cut the bookmatched pieces to length and have placed them on the workbench and belt sand them to remove saw marks. I like to set the pieces on a piece of 60 grit sandpaper to help hold them still while I sand them with the sander.

Bookmatched pieces sanded to 220 grit.

In this next photo I am tracing the outlines of the pattern onto sticky-back label paper,using carbon paper.

After cutting out the pattern sections I peel off the backing and place them onto the wood blanks .Ready for cutting

I use a #3 reversed tooth blade to cut the pieces splitting the pattern line. Take your time-stay on the line.

I purposely cut the outsides of the pieces a little heavy so I can adjust the fit with a little sanding for a good fit.

After removing the pattern from the pieces I use a 1/2” drum sander on the roto tool to round off the edges and sand the pieces with 320 grit. At this point I have cut a pattern and placed it into the box lid.I also have applied a coat of spray-on poly and wiped it off and set the pieces in place.

The bookmatched Lacewood should really look good after all of the finishing is done. Next segment will be cutting out the rest of the intarsia.

-- Mike --

6 comments so far

View jockmike2's profile


10635 posts in 4275 days

#1 posted 11-30-2009 06:06 PM

Very cool project, can’t wait for the finished piece.

-- (You just have to please the man in the Mirror) Mike from Michigan -

View dustbunny's profile


1149 posts in 3324 days

#2 posted 11-30-2009 06:13 PM

I’ve been following your box blog, and was anxiously awaiting this one, and now the next one.
The lacewood almost has a textured leather look, which is cool with the buffalo.
Excellent blog work!!


-- Imagination rules the world. ~ Napoleon Bonaparte ~

View Dan'um Style's profile

Dan'um Style

14173 posts in 4012 days

#3 posted 12-01-2009 02:37 AM

looks like a lot of fun

-- keeping myself entertained ... Humor and fun lubricate the brain

View grizzman's profile


7836 posts in 3332 days

#4 posted 12-01-2009 02:44 AM

im glad this part came…im looking at it thinking there are some mighty small piecies to be cut..thanks for doing this…and as i see the back ground of your shop…i feel ok about mine also…i thought..hey..its my shop..if i can live with some clutter..then hey…all is good…..after all…after i saw mikes shop…im almost like martha stewart…lol…...

-- GRIZZMAN ...[''''']

View wdkits1's profile


215 posts in 3382 days

#5 posted 12-01-2009 03:15 AM

Thanks for looking everyone. This is turning out to be a fun little project. To Grizzman—hey, who’s got time to clean when you’re having so much fun. LOL, I know where everything is—it’s in here someplace!!! As far as the intarsia, the fun has just begun. To make the buffalos look good there will be lots of detail carving and texturing and the fence parts are miniscule but that’s what makes it a challenge.

-- Mike --

View paulcoyne's profile


133 posts in 3149 days

#6 posted 12-01-2009 05:17 AM

this blog is a definite follower so informitive, i check in every day waitng for the next post which sounds silly but its just so informitive its like a private tutorial… thanks mike

-- thats not a mistake... i ment that

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