This is how I did it. I thought about building a jig that was adjustable but I just knew it would not meet my expectations regarding accuracy of inlay alignment, so I went with a set size/shape inlay jig. I figure now that I know what I'm doing I could build another one with a different shape in a few hours. The first photo shows the underside/Inside of the jig, the pink lined cauls each have 2 threaded knobs that move independently for micro adjustment once placed and tightened on the guitar. This was very helpful in getting the inlay aligned just right. The pink foam padded cauls were also shaped to the radius of the top and back for a cleaner fit/grip. I used a circle cutting jig to cut the inlay pattern in the plywood jig, This enabled me to make a perfect/smooth pattern which allows for the tight fit seen. I also used an inlay bit set in the router which makes the task fool-proof. You place the jig on top of the guitar, align the inlay pattern accurately with the set/clamping screws(pink lined pieces, and their adjustable tightening knobs, the adjustable feature is very important or the jig just wants to move into one set position which most likely is not accurate) cut the receiving slot for the inlay, remove the jig and place on top of another block(tighten), which holds the inlay material, remove the bearing on your inlay pattern bit, cut the inlay itself, remove and you have a perfect fit. I also cut the inlay piece approx. .010 thicker than the depth of the slot receiving it, a little sanding and your done. If you want to run purfling along the edge of the inlay piece just wrap the appropriate amount of tape around that section of the bearing guide that follows the inlay pattern jig while cutting the inlay itself and that will leave a gap for the purfling.
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Cheers,
Greg
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