OK so the box is done and ready to do the inlay work. The top of the lid was made to allow 1/4” stock so I resawed the background woods(Peruvian Walnut and Maple) to 1/4” and planed them down to 3/16”. The inside of the box lid is exactly 5” x 6” so the outer background blank (Peruvian Walnut) is cut to the approximate size, then using the jointer , miter saw and belt sander I sneak up to the final measurements for a perfect fit. It is important to allow 1/16” on the length and width to allow for seasonal expansion.
I printed 2 copies of the pattern onto sticky back label and cut one to fit the Peruvian walnut background, adhered to the blank , drilled a pilot hole to insert the blade and cut the center section of the oval using a #2/0 skip tooth blade. Take your time -stay on the line.
Sometimes it may be necessary to use mineral spirits to remove the pattern and residue. At this point I sand the piece with 220 grit. I use a 1/2” drum sander on the dremel to smooth out any irregularities in the cutting.
The second copy of the pattern is attached to the maple and using the just cut oval (Peruvian Walnut) as a pattern, trace the exact shape of the oval onto the maple blank. (Makes up for any mis-cutting) I use a .5MM mechanical pencil for all tracing from now on. I now change over to a #3/0 blade for all cutting. Cut out the inner oval and use the 1/2” drum sander if necessary to get a good fit.
Having fun now—Stay tuned
-- Mike --www.midlothianwoodworks.com