Instructions for making the Double Block inlay.

You’ll have to build both the 45 and the 22 1/2 jigs as well as cut stock to yield 16 – 22 1/2 pieces.

You will also need gluing clamps. Here’s how I made mine. Cut some 3/4 ” plywood into 2 1/2” squares, you’ll need 8 of these. Glue them up in pairs. Cut the glued up squares 1” in on 2 sides and the knock off the corners on a 45 angle. This will yield 4 clamps, two sets.

We want to introduce another element in here, a rectangular piece of contrasting wood. The final goal is to produce a trim band that looks like they are individual square blocks. I’m sure someone out there can give us the math to figure this out, but I’ve just used eyeball, guess and by golly to get it close. I want the finished handle to be 1 1/8” round. This means that as we add additional pieces of wood our block is going to grow. I have found that 1/8” wide strips are darn close. So cut 16 strips of your contrasting wood to place in between each of these small wedges, glue them up and clamp. (Make sure to use wax paper around the piece or you will glue the clamps to it.) It’s possible to add a 3rd color here by using 8 pieces of one type of wood and 8 of another. You’ll end up with a rather large hole in the center of this glue up. You can drill it out and fill it with a dowel or I use body putty to fill it in. Either case you’ll need to drill your mandrel hole later.

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