DIY Network

Inlay Broach From "Woodturning Techniques" episode DWTT-108

This broach is made from red heart wood, but is decorated with a maple inlay.

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Steps:

1. The broach face has a slightly domed shaped surface (figure A). The turning process is the same as the red heart broach turned previously, but once the face is turned, a parting tool is used to turn a shallow, flat recess for the inlay (figure B).

Figure A

Figure B

Figure C

2. The lathe is turned off, and with the flat part of the tool flush against the disc, it is checked for a flat surface (figure C).

Figure D

3. The red heart disc is removed and a maple disc is mounted in the chuck. Since only a slice of this blank will be used, a pencil mark is made on the blank at the point where it enters jaw #1 (chuck jaws are numbered). By marking this spot, each time the blank is mounted in the chuck, it will center back up very closely without having to be trued again (figure D).

Figure E

4. After trueing the cylinder, the diameter is matched to the size of the recess in the red heart. The parting tool is used to turn the maple blank close to the size of the red heart recess, then the recess is held up to the maple blank until they match. When they match, a fairly thick disk of maple is parted from the blank (figure E).

5. The red heart is remounted in the chuck, and the maple inlay is glued to the recess in the red heart with fast drying glue.

Figure F

6. Light passes of the tool clean the face of the inlay and blend the two woods into one smooth surface. A clean cut is needed to blend the two woods together. This step is tricky since there is just one chance to get it right (figure F).

7. Using double-sided tape, the inlay disc is mounted off-center on a plywood disc and accent lines are marked with a pencil (figure G). One pass of the spindle gouge cuts the accent into the disc (figure H).

Figure G

Figure H