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 --www.midlothianwoodworks.com