Tutorial: some intarsia how to

[workin for wood]

This is a section of a fairy wing. It's a wing that is thin and small because it is just a tip of a wing in the distance. It is a good little lesson for those interested in some intarsia technique.

Pic 1, the pattern is traced to the wood using carbon paper. This particular piece is gang cut because it has a split down the center and a cut on either side. The even number of cuts will create an even finished project. There are hundreds of situations encountered in intarsia, and this is just one of them, but the basic trace, cut method is the same in all. This piece is traced and then it is cut out around the outside, leaving the inner lines intact.

Pic 2. After cutting, the tearout on the bottom is removed...this is the first thing you do every time you finish cutting out a piece. Then the edges are sanded on a spindle sander. This guarantee's a clean square edge.

Pic 3 The next piece is traced onto the wood using the pattern and the finished piece at the same time. In this instance, the pattern isn't even needed, so it is traced in and then the outer line is freehand. Pay attention to grain direction at all times. The direction of grains fools the eyes to look in certain directions, which is part of the 3 dimensional look.

Pic 4 This is what I call an exit cut. I cut in on an angle to relieve the actual cut of the piece which will come in from the other side. Organizing how you make cuts is a key to success.


Pic 5 Now you see the round part of the piece cut. It is still attached to the board with empty room on either side. This is because it is such a tiny piece. The cut is just a hair outside the line. The board is moved to the drum sander and shaved down to the line, being squared up at the same time. If a cut is going to be slightly off square, it's most likely to happen with thicker woods and while turning a bend. This calculated cut fixes that, and also the piece is just too small to safely hold on to otherwise.

[workin for wood]

Pic 6 The new piece is completely cut from the board now. This is an exageration to show what often happens when a new piece is added. The two edges don't line up flush, but they are supposed to. This problem is quickly repaired using the spindle sander again. For this piece, I am able to simply hold the two pieces together while I sand them flush, but otherwise I would use masking tape to hold them together. I trace, cut, match then masking tape each piece until I have them all cut and fitted.

Pic 7. This is the final additional piece. You can see it is placed onto the pattern and the edge is used while tracing along with the pattern itself for the next piece.

Pic 8. With the new piece cut out, it's time to jump to shaping. Yes, what about the lines drawn on the original piece ? ...patience is key here.
Set the wing to the head and mark a line so that the highest point of the wing won't exceed the lowest part of the head.

Pic 9. Using the belt sander, the piece is flat sanded down to the line. Then it is sanded on an angle so that the top is slightly less thick, because the top is facing furthest away. Then round the outer edge as much as possible.

Pic 10. This is what it should look like now.

[workin for wood]

Pic 11. The spindle sander is used to bevel the inside area due the the sharp curve. The belt sander is used to bevel longer straighter edges.

Pic 12. The profile is traced onto the next piece, then a line is drawn to angle it down even more. Then it is sanded to match.

Pic 13. The same is done here. The profile is traced and the next piece is shaped down to size. Notice now the lines have been re-drawn onto the main wing piece. This was done simply freehand, where close is good enough. Now those lines can be cut and the larger section will become 4 pieces.

Pic 14. The 4 pieces are simply beveled on the edges because there is no need to shape them individually...that's already happened! Be sure the other pieces are beveled too, then hand sand all the pieces.

Pic 15. A very small bead of woodglue on the bottom edges and the project is glued together for a sweet tight perfect fit.