On the last segment I went over the basics of tracing, cutting and sanding so now I will go into some of the details of carving and contouring that make intarsia unique.
After a piece has been traced,[including carving lines as per pattern] and sawn out, now is the time to carve in the details.
In this photo I have placed a sheet of 60 grit sandpaper on the workbench and have placed the piece on it. Using a 5/64” high speed cutter I carve the lines thru the paper pattern at a 45 degree angle while holding it down with my thumb nail. When all lines have been carved I remove the pattern and check to make sure that all lines are uniform. I re-carve if needed.
Once I’m happy that the carving looks good I shape the edges with a 1/2” or 1/4” sanding drum then clean the surface with 220 grit sandpaper. I then check for fit and adjust if needed.
In the next photo the pattern calls for C9 Pau Amerrillo which is 1/4” next to D9 Pau Amerrillo which is 3/8”. The arrows on the pattern indicates that the D9 has to be contoured so that the two pieces are the same thickness where they meet. For this I use my 3×18” belt sander and work it down along the edges until the 3/8 is close to 1/4”. I do the final shaping with the 1/2” drum sander and 220 grit sand paper. Once I am happy that it looks good I spray on a coat of satin poly and wipe off. Check for fit and adjust if needed.
This next photo shows what the contouring should look like.
Well this has been a good day. I managed not to lose or break any pieces and things have fit together pretty good without alot of adjusting. It is important to trace and cut the pieces accurately and not to get in any kind of a hurry when shaping and sanding.
Woods used so far: Poplar—grass ;Mahogany—road ; Blue Mahoe—bush ;
Maple—Bumper, rims and headlight trims; Holly—headlights; Ebony—fenderwells and front grill; Wenge—tires; Pau Amerrillo—truck body
-- Mike --www.midlothianwoodworks.com