How would you cut this inlay....

[Dennis Peacock]

OK.....I am needing to cut several diamond shaped designs in the sides of a custom CD Cabinet. The center of the diamond is the actual side of the cabinet. All I am wanting to do use cut about a 1/2" groove in a diamond shape and put pieces of 1/8" by 1/2" exotic wood to make the shape of the diamond.<BR>
Here is a diagram:<BR>
<img src="http://home.alliancecable.net/~tapmomof4/diamond-inlay.jpg">
<BR>
So you see...the center will be the red oak panel that makes up the sides of the cabinet.

My question is: how do you cut this out without multiple inlay patterns?

[Bob Lasley]

Dennis,

I suppose there are a number of ways to do this. One would be to use your inlay bushing set and a half diamond template with just the area you want to route cut out. Lay the template where you want the top half of the diamond and rout that, then flip it over and do the bottom half.

Another way would be to make a full diamond template for either the outside or the inside and use a guide bushing and 1/2" straight bit. I think if I were using this method I would stop short of the points and then finish up with a sharp chisel so that you would have nice crisp points. Then rip 1/8 x 1/2 strips and miter them at the corners.

Hope this is a little clearer than mud. If not, call me.

Bob

[Daniel Rabinovitz]

Say Dennis
It looks like two squares to me.
How about an inside square held in place with double stick tape or two small pin nails.
And an outer square template.
Does that make sense?

I had to replace some garage door panels awhile ago and made a square outside template out of 1/4 hardboard. Cut the panel out with a top bearing 1/2 inch router bit. Then replaced the panel and held it in with 1/4 round.

[Jamie Buxton]

Dennis --
I'd use just one template, a plunge router, a 1/2" bit, and a template guide.

The template would have a square hole in it. I make that kind of hole on a table saw. I hold the template stock against the rip fence, with the blade fully retracted. Then I plunge cut into the middle of the template stock by cranking up the saw blade. Like all plunge cuts, this has the potential to get away from you, but if you pay attention you'll be okay; I've been doing it for years. I use MDF for template stock; it has no grain to grab the saw blade, and machines very easily.

I'd clamp the template to the workpiece, push the router firmly to the edge of the opening, and plunge the bit down into the workpiece. Run the router clockwise around the template opening, so that the bit is pushing the router against the template. Square up the corners with a chisel.