Scroll Saw Challenge

[Dave Monk]

I was commissioned to design and craft this gift box. Normally I do a double bevel inlay. Many times it is hard for me to hide entry holes on certain colors of wood. On this project I made my pattern with super thin lines. I used a #1 blade and carefully cut all the pieces separately and glued them together. Walla..........no entry holes to have to try to disguise. I lined the bottom with velvet. Sorry for the blurry picture.   Give it a try. Use 3/8" or 1/4" wood. 

[Scrolling Steve]

Beautiful!

[Scrappile]

That is some precision cutting for sure.  Beautiful!

[rjweb]

Dave, another beautiful project you have done, let me get this right, you cut each piece separety and glued it up and it is actually an inlay ?, RJ

[Dave Monk]

7 hours ago, rjweb said:

Dave, another beautiful project you have done, let me get this right, you cut each piece separety and glued it up and it is actually an inlay ?, RJ

I would consider it and inlay because different pieces of wood got into another. 

[Gonzo]

Very, very impressive!

[Hudson River Rick]

@Dave Monk

Dave, another piece of outstanding design & cutting.  Thanks for sharing.

WOW

Rick

[Denny Knappen]

Mighty fine cutting

[DickMira]

Another beautiful project demonstrating superb craftsmanship.  Thanks for sharing. Dick Mira 

[AUTOMILE]

Awesome work!

[heppnerguy]

Truly you are an amazing scroll saw artist. Always enjoy seeing you win one more challenge. 

Dick

heppnerguy

[Gonzo]

I know I’ve already commented, however Im thinking of taking you up on the challenge. Therefore I do have a question. Did you cut the parts at 90 degrees or did you have the blade at an angle?

[MarieC]

I am with Matt @Gonzo on this one.  What angle did you set your blade in order for the pieces to not fall through?   Wonderful work as always! 

[Dave Monk]

21 hours ago, Gonzo said:

I know I’ve already commented, however Im thinking of taking you up on the challenge. Therefore I do have a question. Did you cut the parts at 90 degrees or did you have the blade at an angle?

I did them at 90 so it would look good on both sides. Most of the time I use a double bevel inlay method. That is where you stack one piece on top of the other, set your saw at an angle and cut through both. Using that method you have to have an entry hole. 

[Dave Monk]

2 hours ago, MarieC said:

I am with Matt @Gonzo on this one.  What angle did you set your blade in order for the pieces to not fall through?   Wonderful work as always! 

They will fall through.  I put glue on the sides of the pieces and glue them in. I try to make my cuts good enough that there is little of no gap. 

[Charlie E]

On 11/6/2025 at 12:27 PM, Dave Monk said:

They will fall through.  I put glue on the sides of the pieces and glue them in. I try to make my cuts good enough that there is little of no gap. 

No problem. Just cut perfectly straight lines and do it twice rather than once. Fantastic work, Dave!

[JTTHECLOCKMAN]

Dave I had to take another look at this piece and have to say this is extrordinary not only finish results but the method used. I like the others need abit more explanation as to the method. Now I have done a few projects over the years where I tried cutting pieces out and laying them within the base piece but no matter how hard I tried there is always gaps. yes very tiny but my OCD gets the best of me. The reason for the gaps is the kerf of the blade. I tried to cut on one side of the line for the base and then cut on other side of the infill piece if that makes sense. I figure this should make up for the kerf of the blade. No matter what size blade you use there is a kerf. I can cut 2 circle pieces seperately an lay them on top of one another and no way are they going to be exact cuts and mirror each other. Now this method you can say plays a roll in Intarsia by the way you lay pieces next to each other. But there you can cheat by sanding to make a better fit.  Now I consider myself a fairly good scroller with a steady hand and keen eye. I use a good saw and good blades but have to say if you can do what I think you are doing you are a far superior scroller than I ever can be. 

Is there a video or other photos of your process that you can share? If not can you make one. Or maybe with more detail explain this method so we all can enjoy the fruits of your labor. This technique is quite rare especially when talking detail work such as you shown. Your double bevel inlay work is out of this world on its own but man this is topping that. Thanks.

 

Dave I have looked through your album that you post on FB many many times because right after you show another piece of art it just draws me to it. I have to say there are many talented scrollers here but you have to be the best of the best. Your Intarsia work is out of this world for many reasons. The ideas and projects are well thought out and the woods chosen go all so well. The cutting is first rate. Those of us who use the scrollsaw know the time and difficulty that is involved in pieces you make. No machines to sit back and watch them cut by themselves and no outside help from aliens. Then you take scrolling and woodworking in general to new levels by making other projects such as boxes and planters and so on. This is not a remark made to embarass you but is a remark to praise you and to applaud you for the work you do and give you the accolades you deserve. I hope others can check your work out and follow you and you continue to give us the pleasure of enjoying your talents. Now I have to say there are a few projects that at some time in my remaining years to be able to simulate and add my own touch to your ideas if you do not mind. But when doing them I will be continuing asking myself what would Dave do in this situation. Thanks again for sharing. 

Edited November 17, 2025 by JTTHECLOCKMAN

[wombatie]

Another amazing piece.  Great work Dave.

Marg

[Roberta Moreton]

You ARE a master of the box!