Decorative inlays inlay kits

Instructions for Building Any Inlay --- Cutting Inlays

Cutting the Inlay

WHAT you're doing:

Affixing the template to the inlay material, securing the assembly to the workbench, setting the depth of the cut and routing the inlay.

Take the Router BUSHING OFF

WHAT you're doing:

  • If routing an Inlay the bushing is taken off the router inlay kit.

 

WHY you're doing it:

  • To position the router bit correctly inside the template.
    • If you DON’T take the bushing off the inlay will be way to small and not usable.

 

HOW to do it:

  • Firmly pull the bushing off the collar.
Remove the bushing from the brass inlay kit when cutting out an inlay

Bushing OFF the brass inlay kit

Set the Cutting Depth on the Router

WHAT you're doing:

  • Adjusting the depth of the cut made by the router bit.

 

WHY you're doing it:

  • The router bit has to cut all the way through the inlay material.
    • Don’t cut to far into the backing material because the deeper the cut the harder it is to make an accurate cut.

HOW to do it:

      • Each router is different — follow the instructions on your router to set the depth.
When cutting out an inlay the depth of plunge the router makes must go all the way through the inlay material.

Setting the depth of the cut

Cutting the Inlay

WHAT you're doing:

  • Carefully cutting the inlay from the inlay material.

 

WHY you're doing it:

  • To cut out the decorative inlay pieces.
    • Take your time to do this step right!

HOW to do it:

  • With the router off, make a practice pass around the outline of the hole in the template.
    • Router bit not extended yet.
    • Get use to the contours of the shape being cut.
  • Position the collar against the wall of the template.
  • Turn the router on.
  • Plunge the router into the inlay material.
  • Guide the router around the shape keeping the collar, surrounding the router bit, in constant contact with the wall of the template during the routing process.
    • Think of guiding the router like helping that little old lady across the street — you want to guide and firmly support her but not jerk on her arm!!!
  • After the pass is complete turn the router off and carefully raise the router bit.
When cutting an inlay the bearing MUST remain in constant contact with the template wall.

Bushing in contact with template wall

If the bearing loses contact with the template wall during the routing process the inlay piece will be ruined.

Bushing away from template wall

After routing the inlay debris will be around the inlay piece.  Remove the debri to remove the inlay

Routed inlay

Remove the Template

WHAT you're doing:

  • Prying the template from the base material.

 

WHY you're doing it:

  • So you can remove the inlay piece just cut.

 

HOW to do it:

  • Slide a paint scraper (mine is 3″ across) between the
    template and the wood to pry them apart.
    • Denatured alcohol helps remove the tape.
  •  Wiggle the scraper around to loosen the tape around all the areas where tape has been applied.
  •  Don’t pry to hard on the template or it can be damaged!
  •  Peel off the duct tape from the template and base material.
    •  The longer the tape is stuck to a surface the harder it is to remove.
After routing the inlay gently pry the template off the inlay material using a paint scraper.

Prying the template off

Remove the Inlay Piece

WHAT you're doing:

  • Removing the inlay from the inlay material.

 

WHY you're doing it:

  • So you can use it!  :)

 

HOW to do it:

  • Remove the debris from the path of the router bit.
    • I use a shop vac and a pick to remove the material.
    • Removing the debris can make it easier to remove the inlay without damage.
  • Use a pick or a small flat screwdriver to pry out each piece
  • Remember there is double-sided duct tape holding the piece to the backing  material so take your time and be careful so you don’t damage the piece.
    • Denatured alcohol helps dissolve the adhesive on the tape making it easier to remove.
  • It is a good idea to label each piece as you remove it to make assembly easier.
    • Especially important if cutting multiple pieces.
    • Keeps track of which side is up.
After routing the inlay you need to pry iit off the backing material. A small pic works great for this task

Prying the inlay out

Remove the bushing from the brass inlay kit when cutting out an inlay
When cutting out an inlay the depth of plunge the router makes must go all the way through the inlay material.
When cutting an inlay the bearing MUST remain in constant contact with the template wall.
If the bearing loses contact with the template wall during the routing process the inlay piece will be ruined.
After routing the inlay debris will be around the inlay piece.  Remove the debri to remove the inlay
After routing the inlay gently pry the template off the inlay material using a paint scraper.
After routing the inlay you need to pry iit off the backing material. A small pic works great for this task
Remove the bushing from the brass inlay kit when cutting out an inlay
When cutting out an inlay the depth of plunge the router makes must go all the way through the inlay material.
When cutting an inlay the bearing MUST remain in constant contact with the template wall.
If the bearing loses contact with the template wall during the routing process the inlay piece will be ruined.
After routing the inlay debris will be around the inlay piece.  Remove the debri to remove the inlay
After routing the inlay gently pry the template off the inlay material using a paint scraper.
After routing the inlay you need to pry iit off the backing material. A small pic works great for this task