I was recently tasked to make several hardware display boards by a local kitchen cabinet distributor. The customer wanted an inlayed contrasting color border, some of which were 3' long. Never having attempted anything like this before, I was at a loss for a method of cutting 3' long X 1/8" wide X 1/8" thick stock that had to be VERY accurate. After playing around with various methods, I tried one that was fairly simple that yielded very accurate, repeatable results.
I thought I'd share my findings and hope it comes in handy to those who encounter this problem. There may be better ways, but this one worked pretty slick. I was able to cut 60' of inlay in about an hour.
Take a skim cut on one edge of stock. Reverse the stock and take another skim cut on the opposite edge to ensure two parallel sides.
Pic 1. Loosen fence and snug stock between the fence and the blade.
Pic 2. Install a dial indicator on a mag base up against the fence and zero the indicator. To achieve the desired width of the inlay strip, move the fence towards the indicator a distance equal to the thickness of the blade (measure with a dial caliper) plus the desired width of the inlay strip and lock the fence.
Pic 3. Remove the indicator and cut the stock. You must install a zero clearance insert in the saw to prevent the cut strip from curling and use an adequate push block.
Pic 4. Strip cut. I achieved a variance of no more than .004 in 3 feet.
Pic 5. Installed inlay.
Good luck.
Lou
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With the gripper you really do have complete control with the cut, and things do not shift around, like the little 90º piece that is left behind on cut off part as you move the wood along the fence. I assume that you cut all the inlay longer than you needed.
Originally Posted by Lou Morrissette
