Let me start at the end of this project since that is the best look, everything else will be an explanation of how I got to this point. When I made the crib, I cut more of the Walnut pyramid shaped blocks than I needed thinking there could be a future use for them.
|Final Smoothing Done|
I used a piece of Maple and banded it with Walnut on both edges. Those are the materials the crib is made of. This is after all of the machine work was completed and the surface is now ready for several coats of super blonde shellac. Wanted to do that today but it was pretty close to 90 degrees and it would have dried way too fast so it'll be a morning project. In the class I just taught we spent a little bit of time on using planes to achieve the final surface as opposed to sanding. The bronze, #4 Smoother Plane you see at the end of the board is perfect for this. This picture is with natural light, no flash, and you can see some of the gleam in the lower right hand corner of the piece. Can't get that with sandpaper, it's only with a keen cutting edge that you can achieve that look!
|First steps after Laminating|
The next step was making a template that could be used to remove the waste for the Walnut pyramid inlay. In this case I used a piece of MDF, calculated the opening size and then drilled holes in each corner. A simple coping saw is ideal for this step and takes very little time to complete.
|Chisel in MDF|
MDF, being layers of tightly compressed paper can be filed easily. I thought I'd experiment and see what a chisel would do instead. I used one of my "beater" chisels and as you can see, the layers of paper cut cleanly.
Whoops, needed to make two cut outs before I got it right. I almost wonder if I should have just traced the inlay onto the board and worked it free-hand ..... maybe next time.
After using a plunge router equipped with a guide bearing and a 1/4" straight bit the recess was finished off with a small router plane and chisel.
|Router Plane & Chisel to finalize Inlay|
|Look at that Spiral!!|