How do you make wood inlays?

Wood inlays are a beautiful way to decorate furniture, boxes, and other wood projects. The intricate patterns and designs created by contrasting different colored woods can really make a piece stand out. While wood inlay work requires some specialized tools and a lot of patience, the techniques are approachable for any woodworker with some basic skills.

What is wood inlay?

Wood inlay is a technique where you cut channels or cavities out of a solid wood surface and insert thin pieces of wood inside to create patterns, designs, borders, medallions, and more. The thin wood insert pieces contrast with the main wood body to form the inlaid design.

Some common examples of wood inlay projects include:

• Decorative borders on tables, cabinets, boxes
• Intricate medallion designs on tabletops
• Bowl and tray decorations
• Chessboard squares
• Guitar fretboard inlays

The possibilities for wood inlay designs are endless! From simple patterns to complex scenes, you’re only limited by your imagination and skill level when it comes to creating wood inlays.

Tools and Materials Needed

While you can make simple inlays using just standard workshop tools, creating intricate inlaid pieces typically requires some specialized tools and supplies. Here are some essential items you’ll need:

Router and router table

A router and router table setup is crucial for cutting precision cavities and channels into the main wood body to accept the inlay material. You’ll need a router capable of slow spins with large diameter bits installed.

Inlay kit

An inlay kit contains essential specialty bits like straight bits, core box bits, and V-groove bits used to cut channels and cavities.

Hammer and chisels

Small carving chisels help trim and tune inlay pieces so they fit perfectly into the routed channels.

Veneers

Thin veneer sheets, typically 1/42″ thick, make the best inlay material and provide a wide variety of wood colors and grain patterns to work with.

Glue

Use high quality wood glue suitable for fine woodworking. Small bottles with thin applicator tips help apply glue into the inlay channels.

Clamps

Spring clamps or other rotatable C-clamps allow clamping the inlay pieces into channels from various angles.

Wood backing

Use a material like MDF as a backing board when cutting inlay channels through the full thickness of a workpiece.

Dyes and finishes

Apply stains, dyes, or other coloring to the inlay materials to help them stand out more vividly against the main wood surface.

How to Make Wood Inlays

The basic wood inlay process involves five main steps:

1. Design and prepare the inlay pattern
2. Cut channels into the main wood body
3. Shape and fit the inlay pieces
4. Glue the inlay into the channels
5. Sand and finish the inlaid surface

Let’s look at each step in more detail:

1. Design and Prepare the Inlay Pattern

Start by creating a design drawing showing the shapes and layout of each inlay element. Convert this to a full-scale pattern that you can trace onto the wood surface. Acrylic templates for geometric shapes or paper patterns work well. Install any guide bushings needed for the router bit on the base plate. Prepare your wood stock by sanding and jointing the surface flat.

2. Cut the Inlay Channels

There are two main methods of cutting channels for inlays:

Routing partway through the wood stock

For simple inlay borders or patterns, cut channels approximately 1/16″ deep into the wood surface using a straight or core box router bit matched to the inlay thickness. Leave at least 1/16″ of wood below the channel.

Cutting through the full thickness

For complex inlaid patterns or replacing sections of wood, cut all the way through the workpiece thickness. Use a backing board underneath to prevent tear-out on the back side. Cut overlapping channels and use multiple inlay pieces for wider designs.

Take light passes when routing channels to slowly approach the final depth. Test fit your inlay pieces as you get close to the full depth.

3. Shape and Fit the Inlay Pieces

Use a jewelers saw or scroll saw to cut out your inlay shapes from the veneer material. Carefully shape and tune each piece with sharp chisels and files until they press fit neatly into their corresponding channels. The goal is a tight friction fit without having to force the inlay into place.

4. Glue the Inlay into the Channels

Dry fit each piece to confirm a good fit before gluing. Apply a thin coat of wood glue into the channels using a small applicator tip. Quickly position each pre-fit inlay piece and use spring clamps to apply pressure down into the cavity while the glue dries. Wipe away any excess squeeze-out glue immediately.

5. Sand and Finish the Surface

Once the glue fully cures overnight, sand the surface flush starting with 120 grit and working up to 220 or 320 grit. Be careful not to sand through the thin inlay material. Finish by applying your choice of stain, dye, oils, lacquer, or other top coats to protect the wood and enhance the appearance of the inlays.

Inlay Design Tips

Follow these tips when planning your custom wood inlay patterns:

• Use thin inlay strips for delicate accent lines or decorative borders.
• Stack multiple borders or intersecting patterns for a striking visual effect.
• Combine wood species with dramatic color contrasts for vibrant inlays.
• Accent the inlaid areas with darker stains or dyes.
• Inlay around moldings, edges, handles, and hardware.
• Experiment with geometric, nature, cultural, or abstract inspired motifs.
• Integrate wood burning, carving, or metel leaf accents.

Common Wood Inlay Patterns

Here are some classic inlay patterns that work beautifully for all types of wood projects:

Herringbone

The zigzag herringbone pattern provides visual motion and interest. Build it from small triangular strips of alternating colors.

Sunburst Medallion

A dramatic sunburst inlay makes a bold statement on tabletops. Cut tapered rays of wood radiating out from a central circle.

Chevron

Chevron striped inlays add dynamic diagonal lines. Use contrasting right triangles to form the zigzag stripes.

Marquetry

Marquetry utilizes intricate cutout pieces assembled into a mosaic-like image. It requires very precise cutting and assembly skills.

Celtic Knotwork

Intertwining Celtic knots formed with rope-like strands of contrasting woods have an elegant, old-world look.

Dutchman Inlay

A Dutchman inlay is a solid wood patch piece used to mend damaged wood by replacing a missing section. Useful for repairs and restoration work.

Butterfly Keys

Butterfly keys are bowtie-shaped Dutchman patches inserted across the grain on table cracks and defects. The ends flair out decoratively.

Common Woods for Inlaying

The specific wood species used will depend on the desired look, but some good choices include:

Wood Type	Characteristics
Maple	Creamy white color, tight grain
Walnut	Rich brown tone, visible grain
Cherry	Golden red hues, smooth grain
Bloodwood	Bright crimson red color
Ebony	Deep black color
Beech	Pale tan color, subtle grain
Mahogany	Warm brownish red tones
Padauk	Vivid orange-red color
Maple burl	Wild, chaotic figuring

Some general tips on selecting inlay woods:

• Use woods with striking color contrasts between the main surface and inlays.
• Harder wood species hold intricate shape details better.
• Consider grain patterns and texture contrasts.
• Exotics offer dramatic colors but can be pricey. Domestic hardwoods work very well.

Troubleshooting Wood Inlays

Here are some common wood inlay problems and how to avoid them:

Inlay pieces are too loose in channels

Tune the fit with light sanding or shaving until pieces fit snugly without falling out when tipped vertically.

Inlay pieces don’t fit fully into channels

Re-route the channels slightly deeper. Make multiple light passes to slowly approach the depth.

Glue squeeze-out stuck on surface

Wipe away excess glue immediately before it dries using a damp cloth. Gently scrape dried glue carefully after curing.

Chips and tear-out around inlaid edges

Use a sacrificial backup board when routing channels through the full workpiece thickness.

Edges around inlay pieces visible

Sand surface flush starting with 120 grit paper up to 320 grit, taking care around thin edges.

Inlay pieces shrinking or swelling later

Make sure inlay and substrate woods have reached equilibrium moisture content before assembly.

Best Practices for Quality Inlays

Follow these top tips to help execute professional quality inlaid designs:

• Use ultra sharp router bits and replace when worn.
• Work slowly and make light passes when routing channels.
• Cut inlay pieces slightly oversized then tune for precision fit.
• Use backing boards to prevent blow-out.
• Clamp in multiple directions to seat pieces fully.
• Let glue cure fully before sanding and finishing.
• Pre-finish inlay pieces for stability.
• Start finishing with fine sandpaper and finish by hand.

Creative Wood Inlay Ideas

Looking for unique inlay inspiration? Here are some creative ways to use inlays in your woodworking projects:

Geography Map Inlays

Inlay a map of local state or country outlines in contrasting woods. Add cities or personal dates for custom details.

Song Lyric Inlays

Inlay meaningful song lyrics, poems, or quotes in script fonts. Use light and dark woods for distinction.

Family Tree Inlays

Design a family tree diagram with each relative’s name inlaid on branches or within shapes representing people.

Pet Silhouette Inlays

Cut out the profile shape of a pet animal or bird and inlay it into a table or plaque.

tolerant Inlays

Inlay designs featuring tolerant themes or awareness ribbons to match the cause.

Gaming Inlays

Inlay gaming symbols, favorite characters, or memorable scenes on a game table or board game box.

Hobby Inlays

Incorporate a musical instrument, favorite sport, car, or other hobby theme into your inlay artwork.

Monogram Inlays

Inlay stylized or script initials and monograms for a personalized touch. Use first names or couples’ initials.

Conclusion

The art of wood inlay opens up endless possibilities for making decorative impressions in woodworking projects. With some practice using the fundamental steps of designing, routing, cutting, fitting, gluing, and finishing, you can create stunning works of functional art. Approach inlaying with patience and precision, and you’ll be rewarded with professional quality results. Whether going for bold geometric statements or nuanced marquetry, the intricate beauty of wood inlay is a rewarding skill to develop.