Tips/Tricks for Fitting Inlays?

Erin Burke

Erin Burke

Well-Known Member
Cross-posted w/ BF.

Good morning Dogs. I'm working on a set of balisong handles that will have oval-strip inlays of either stabilized bone or G11 (or something). I milled the slots for the inlays using a 3/16" end mill. I also milled some through-pockets in the bottom of the inlay-slots to allow me to easily pop the inlays out as I test fit them. Here's a photo of the rough-milled handles for reference.
5362398187_886f5a30a2_m.jpg

Does anyone have any tips/tricks/jigs for fitting up this type of insert? I would appreciate anyone willing to share their methods? Thanks in advance.

Erin
 
I cut the pieces about 1/8 longer than they need to be. Since you have a mill you can gang mill a stack of pieces to all be the same width, in this case 3/16. Then I carefully radius one end to match one of the pocket. Then start the radius on the other end on the grinder and then file by hand till it fits. If all the milled slots are the same length then you can do the pieces a couple at a time.
 
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