As Jonathan Salisbury finds, this excellently made router inlay kit from the AUKTools brand presents an almost fail-proof method for creating a neat, high quality result.
The Woodworker & Good Woodworking
Making inlays or inserts is relatively easy, as long as you have the right tools. A router is ideal for making a perfectly flat-based recess, of almost any shape, into which the inlay can then be placed. Matching the two up is another matter, however; the more complex the shape, the trickier it is.
The AUKTools inlay kit has been created to help make perfectly fitting inlays and repairs, both functional and decorative. The first step is to make, or buy, a template with the required shape; you then attach the bush to the router using the alignment rod to ensure that it’s central. Next, install the 1⁄8in diameter cutter into your router, set the depth to match inlay thickness, leave the removable collar in place, then rout the hole. Once complete, the collar is removed and the same template transferred to the piece of wood being used to cut the insert; you then need to rout around the template’s edge very carefully in order to create the insert profile.
In use
Of course, this requires a great deal of preparation and care; the template has to be held in place securely, and the insert material also held to something below it, just in case it moves at the end of the cut. This is even trickier if the workpiece is very thin. The simpler the shape the better, and it does work. Even though the 1⁄8in router cutter is small, it’s not able to produce super-sharp corners. If you don’t want to make your own templates, Wood Workers Workshop has a wide range available, and for simple repairs, you can always use a circular hole of the required diameter drilled into a 6mm piece of MDF or plywood.
Trial & error
I first tested the jig using the AUKTools Circular Router Inlay Template, reviewed in the March 2023 issue. That was too easy, so I decided to go to the other extreme with a big W. Cutting the recess was time-consuming owing to the small cutter; I had to finish it with a chisel, but this didn’t present a great challenge. The insert, on the other hand, was difficult. Because I didn’t have a clear view of the cutter, I had to carefully feel my way around so as not to ruin the edges. I almost succeeded. In hindsight, I shouldn’t have used cedar for the base, which chipped on a few of the edges; I thought that if using cork for the inlay proved to be successful, anything would be possible, but in reality, it’s far too flexible.
Conclusion
As I’ve come to expect from the AUKTools brand, this bush is very well made; the finish neat and tidy, and there are no sharp edges. The collar has a tiny rubber ring placed inside to provide grip, and I’m sure it could be replaced when it fails to work. The router base needs to have a 30mm (1-3⁄16in) diameter aperture in which to fit the guide bush; if yours doesn’t, you’ll need to buy a sub-base or adaptor. If you have the right size Forstner bits – 30mm for the hole and a 35mm counterbore to inset the rim, which prevents it touching the surface – it would be easy enough to make from thin ply.
This is an almost fail-proof method of creating a neat, high quality result. With complex shapes, it’s essential to practice first; the ply router base didn’t help, but even if it were transparent, it would still be impossible to see the cutter owing to the brass bush. Simple outlines don’t pose a problem, although they still require care, and whether you’re cutting decorative or functional inlays, the possibilities are increased with the use of this kit. It’s a great time saver too, as long as you don’t produce anything too complicated.
The Verdict
-
Pros: An easy way to create perfect routed inlays; good fun to use
Cons: Requires templates and a router with a suitable base; can be fiddly with thin materials; the small router cutter takes a while to clear larger recesses; difficult to see the cutter, which makes complex insert production challenging - Performance Rating: 4.5 out of 5
- Value Rating: 4.5 out of 5
Click here to download the full article
Shop AUKTools Solid Brass Router Inlay Kit