Replies

1. 
   dmdnk | May 23, 2009 02:39am | #1

   dch,

   I've used a set up like the one shown here:

   http://www.jesada.com/instructions/inlay_kit.html

   If you already have bushings, you may be able to piece together a similar setup with them.

   david

1. 
   daen | May 23, 2009 03:57am | #2

   David,

   Thanks for the suggestion. I have the same type of inlay kit. This isn't quite what I was looking for because it is based on you creating a template first and then using the inlay kit to make both the cutout and the fill piece. The cutout and the fill piece will be shaped to any anomaly inherent in the template.

   My situation is a bit reversed. My metal plate is the fill piece. I need to come up with a template to make the cutout to match the existing fill piece. If I make a template from scratch, any anomalies will show up as a mismatch between the cutout and the plate.

   Clear as mud, right?

   Have a great weekend.

   -dch

1. 
   saschafer | May 23, 2009 04:33am | #3

   How about making the negative template out of some thin, easily worked material, such as 1/4" Baltic Birch plywood or hardboard? You can fabricate it by hand, and get as close a fit to the inlay as your patience allows, even using some epoxy if necessary to build up the edge if you go a little too far.

   Then use that template to rout the recess in the table top.

   -Steve

    

2. 
   dmdnk | May 23, 2009 05:01am | #4

   You would use the piece you have to make a mating (female) template then position that on the workpiece to cut the outline of the recess for the existing piece.  After the ouline is cut,  you switch to a large straight bit to remove the remaining material.

   david

3. 
   Jimurock | May 23, 2009 06:02am | #5

   LV gives instructions that might be useful: http://www.leevalley.com/shopping/Instructions.aspx?p=40701

   Jim

1. 
   rwdare | May 24, 2009 05:31am | #6

   use your inlay kit without the ring to cut the template and then with the ring to cut the hole.

   Dick

1. 
   daen | May 24, 2009 04:34pm | #7

   Dick, Jim,

   Thanks for the suggestions and the link.

   I absolutely had it in my mind that this technique wouldn't work. But after David had suggested it and I told him I didn't think it worked I started thinking it through on my drives to and from work. Being the enginerd type, I even layed it out in CAD.

   And guess what... it works just as you have indicated!

   Thanks again for showing me the light.

   -dch