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I was looking at some of the inlay designs at Depaule (luthier supply.com) like the Japanese Maple Leaf, and was wondering how the wood was cut for that. Does one just cut a close hole and then fill with epoxy? That wood work for ebony, but not many other woods. Thanks

Mike

I've used this particular inlay from Depaule. You are correct that it wouldn't work very well for woods other than ebony. You can only route as close as you can and let the filler do the rest

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John Ressler

Basically, yes. The inlay is glued onto the material to be inlayed and carefully scribed around, then removed. The scribed lines are chalked and then routed. After the inlay is set, any little gaps are filled. I use epoxy and tempra powder. A little fill is acceptable for replica instruments. I believe you can get the full size outlines, but the inlays are some of the only ones that are still handcut, so there are variances to contend with. I have used Andy's inlays for years, and they make beautiful authentic looking inlays for replica instruments.
The shell cutters in Vietnam are unbelievably good, and for the type of work I do, CNC cut inlays are just plain ugly.

As Haans says. You do want to scribe the outline as carefully as you can, remove the inlay then route the chalked lines as closely as you can. Epoxy fill should never be an option. Inlaying in soft and light colored woods makes it much harder to get a good look. (It is easy to cut into the wood outside the inlay with soft woods, and those cuts need to be closed before CA is used or they will forever show. Gaps in light wood are hard to fill without showing.)

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Joe Beaver
Maker of Sawdust

I was trained with David Nichols , and we use a .3mm pencil. In all honesty, the most difficult part is learning to line out the pattern. I like the pencil and it is reflective and I can see it with my light and magnifier. Here is how I do it.
https://www.youtube.com/watch?v=o7gYBqLRdMo

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John Hall
blues creek guitars
Authorized CF Martin Repair
Co President of ASIA
You Don't know what you don't know until you know it

Thanks for that John. I like your pencil application.