Filling Gaps in Intarsia Projects

[jvbscroller]

Sometimes when doing intarsia projects, I find that I have gaps between pieces.  In one intarsia instruction book, I found a great suggestion.  It said to fill gaps with hardwood sawdust moistened with wood glue.  I have found that method effective.  One challenge is making hardwood sawdust from hardwood that matches your intarsia piece.  

I made a workbox and dust collector so that I could make hardwood sawdust and do other small projects.  My objectives were (1) collect dust so my project does not throw dust all over the work area, (2) make it out of materials that can easily be changed, (3) use materials already on hand, if possible. 

Here is a photo of the workbox and dust collector that I made.  The box itself is only a cardboard box approximately 24" wide by 12" deep by 12" high, so it can easily be replaced if I want a larger box.  It has a hole in each end.  On the left the hole is for a drill mounted horizontally.  On the right the hole is for an extension of my vacuum.  I have found this to be effective and easy to change.  

The jig for the drill and the support for the vacuum extension are clamped to the work table.   

    

Here is a photo of the jig to hold the drill.

These three photos show attachments for the drill which I find very useful but tend to throw a lot of dust.

 

 

This tool is called a 'rotary drum rasp' or 'rotary drum drill shaper'.

   

 

The attachment I use for making sawdust is either a sander or a rasp.  For the wood, I use leftover pieces of hardwood from intarsia projects.  I always hold the wood with pliers or grips in order to protect my hands.

      

  

 

Much of the dust falls into the small box, but some gets into the larger cardboard box and I sweep it up.

 

Here are a few photos showing how I have used sawdust to fill gaps.  Sanding afterward is essential.

  

 

        

 

 

 

 

 

 

 

 

Edited September 12, 2020 by jvbscroller
removed unnecessary photos

[jollyred]

Another way to collect dust is to put a box under the bottom arm of the saw.  Any dust that gets past your dust collection (if you have any) will go into the box.  It will be the dust from the pieces used on the intarsia, so will be a good match.  Be sure to empty and clean the box after each specie.  It is surprising how much dust the box will collect.

Tom

[jvbscroller]

Thanks very much for your comment.  Very perceptive.  In the past, I have tried a couple of different methods.  With my tools the best method for me is the method I presented above.  My table saw will not drop the dust into a box.  Your table saw is far better.  One other method I tried was to thoroughly wash and dry the dust collection boot on my handheld belt sander, install a coarse sanding belt, then sand left over pieces of hardwood.  Effective but slow.        

Edited September 12, 2020 by jvbscroller
Updated text for clarification.

[Tomanydogs]

Thank you that was informative. Can you tell me what this is, it looks quite aggressive? Thanks

[jvbscroller]

Thanks for your comment.  You are correct.  This attachment is very aggressive.  It will carve both wood and fingers.  When using this tool, I always use pliers or grips to hold wood.  It is called a 'rotary drum rasp' or 'rotary drum drill shaper'.  If you search the internet for 'rotary drum rasp', you will find several kinds available at various outlets.  

[jollyred]

"My table saw will not drop the dust into a box."

The saw I use for collecting the saw dust is not the table saw, but the scroll saw.  The dust is collected while cutting the intarsia pieces.  Collecting dust from a table saw would not work too well for this.  Sorry if you didn't realize what saw I was referring to.

Tom

[jvbscroller]

OK, thank you.  It's a good suggestion. My scroll saw has no dust collector, but maybe I could try gathering some of the dust that falls on the structure just underneath the table.

[amazingkevin]

You've great ideas your shareing with us. I have way to many project to make the shop better but I'm disabled and what can get done in a chair might get done, thanks for the tips an tricks!!!

[jvbscroller]

Thank you to jollyred for the suggestion about gathering dust from underneath the scroll saw blade.  I was able to make that method work pretty well though I do not have a vacuum on my scroll saw or even a flat area underneath the blade for collecting dust.  To test his idea, I followed this process.  

1.  Clean the area directly underneath the blade.  This photo shows I did not perfectly clean the entire area underneath the saw, but did clean the area directly beneath the blade.

2.  Use a coarse blade to repeatedly cut a scrap piece of walnut.

 

3.  Note how much dust has collected directly underneath the blade and on top of the saw.

4.  Using a small paint brush, sweep the dust onto a dust pan.

 

5.  Add the dust to my jar of walnut dust.  

 

[Frank Pellow]

I've used this technique with success , but I have never gone about it as thoroughly as you.  Thank for all he details.