| Inlaid Corner-Table -- Ebony Inlay and Scarf Joints |
From "Wood Works"
episode WWK-310 |
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Ebony Inlay With the base assemble and the top-piece cut and shaped, the layout can be made for the decorative ebony inlay. Before the ebony stock is cut into thin strips, quarter-inch tape is used as a design guide to mark the position of the inlay (figure A).
Materials: Ebony stock
Hand router; 1/8-inch bit
Band saw
Drum sander
Disc sander
Quarter-inch carpenter's tape
Chisel
Mallet
Yellow wood-glue
Carpenter's pencil
Clamps
Blue carpenter's tape
Safety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his Web site -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, power-tools, saws, drills, routers, etc.
Steps:
- With the tape in place on the top, mark the outline in pencil to create a layout mark for the router to follow.
- Position the inlay about 3/4-inches in from the edge of the tabletop (figure B).
- Use a hand-router with a 1/8-inch bit to cut the channel for the inlay, following the pencil line. So that the router-fence has something to rest against when cutting at the corners, double-stick tape triangular wood blocks to the edges to create a longer surface area (figure C). The longer surface area will help ensure a more accurate cut at the corners.
- Tip: It's advisable to cut the recess in the tabletop before cutting the strips for inlay. That way, if you make a mistake cutting the strips, you can simply widen the channel in the tabletop.
- The channel made with the router is cut 1/8-inch deep and 1/8-inch wide. Stop the cut just shy of the corners, then use a sharp chisel to join the segments of the channel at the corners (figure D).
- With the channel cut in the tabletop, the strips of ebony can be milled up. At the band-saw, cut 1/8-inch by 3/16-inch strips of ebony to fit into the channel ( figure E). The strips are cut just slightly oversized so that it will protrude slightly from the channel. Once glued in place, the trim pieces will be trimmed flush with the surface of the table.
- Once the strips of ebony are cut, run each through the drum sander to take it to its final width (figure F). Use chalk to mark the sides of the strips that will protrude from the channel, to ensure that those sides are not sanded.
- The ebony stock we used was about 14 inches in length. Therefore, several pieces had to be joined together to cover the long runs on the table. To make that joint invisible to the eye, a scarf joint is made.
- A scarf joint is a long, diagonal cut that exposes the long grain of the wood (figure G). When these long cuts are glued together, they create a bond that is almost completely hidden.
- To create the scarf joint, a jig of MDF and a piece of scrap hardwood is made. The jig positions the end of the ebony stock at the precise angle for making the very acute scarf-joint cuts with the disc sander (figure H). The jig also acts as a fence as the long miters are sanded into the ends of the ebony.
- Two additional jigs are made for the disc sander (figure I) to cut angles on the ends of the ebony. Two separate jigs are needed since some ends need to be angled at 45 degrees, while others need to be angled at 22-1/2 degrees.
- Once all of the ebony stock has been cut, milled and prepared, it is ready to be glued in place. Apply blue woodworker's tape along the edges of the channel to help simplify cleanup .
- Add glue to the channel (figure J), and spread it evenly using a thin stick.
- Position the ebony strips in place, and gently tap it into the channel with a mallet (figure K).
- Use wood cauls, covered in cork and wrapped in plastic, to clamp the inlaid strips secure as the glue dries (figure L). The plastic covering will prevent the ebony from sticking to caul.
- Use a sufficient number of cauls and clamps to keep steady pressure along the length of the inlays as the glue dries.
In the segment that follows, the ebony inlay is flushed smooth with the tabletop, the top is attached to the base, and a wood finish is applied.
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RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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