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  1. 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.
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