When I'm doing intarsia I take it in stages; first the whole project is cut. Second I do the first stage of shaping with sanding drums on my drill press and place each piece back together untill I'm satisfied with the basic flow of it. Next I use my dremnel to round all the edges. I find that using the dremnel it seems to leave a sharp line at the edge where you don't use it. I then take a bow sander to remove that. Finally It's good old elbow grease for the final stage which is hand sanding, I start with 150 grit then 180, then 220 grit until I'm satisfied with it.
Pat...