Well this week I started working on my Hall Frame reproduction. I decided to make a prototype on this one. This will help me test out my templates as well as get my inlay skills warmed up. Much like hand-cut dovetails and other techniques that require a certain amount of manual dexterity, router inlay is not something you want to jump into “cold”. And remember, prototypes make great gifts for family members!
This process started with the creation of a few templates from the original tracings and outlines taken from the original frame. These templates were then used to create the prototype in some alder stock I had laying around. Once the basic shape is established, I had to work out the joinery. These joints are nothing short of unusual at first glance. The only way I can think to describe them is “Inlaid half laps”. To make things a little trickier, the pieces are different thicknesses so that the inlay piece stands proud.
The details of this process will be covered in a future Popular Woodworking article, so I apologize for the lack of detail here. But I did want to keep you guys updated on the process since I think its pretty cool.