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Ken, any idea if you have runout on the mini grinder? I mean, at $10 a pop from HF you could dedicate some to a jig just for your rosettes don't you think? If no runout on them I bet they would work well to duplicate inlay pieces as well as routing the channels.

No idea on the runout of the air grinder, Chris. The tool I got from Dave is made by Enco, and I think it runs about $30 for the tool only. I have done two ebony fretboards along with a cherry and an ebony headstock without so much as a hint of stress on the 1/32" bit. I think some caution shown by others is valid, but I am starting to come around to the belief that all the concern is a little unwarranted given I won't be doing the cutting free hand, the cut depth is shallow, and the wood is soft.

Ken

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In that case, I'd say buy a case of PC 310's (if you can find them) and a case of Bosch Colts, and dedicate them all to specific tasks!

That's cool that they're going to have a 1/8" collet for the Colt.

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Good point Ken, I'd just go ahead a do a quick test on some scrap and your questions will be answered. I cut some fret slots with a .020" bit in a maple board with a dremel that had some runout to yeild a .024" slot and it worked fine. I did break some bits but was do to feeding it too fast and taking off too much with a pass. As you can guess that size bit is fragile.
Enco? I'd say it's the same as HF but a different color and made at the same factory in China like the mini mills.
Here's the cheapest place I found some 310s other then Amazon.
http://www.goestores.com/catalog.aspx?M ... tID=207943