Official Luthiers Forum!

Whats the best way to inlay block shell (as in a Les Paul) into a fingerboard? The radius will be 12". How do you handle the curvature?

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A higher purpose for wood.
Rich Smith
Issaquah, WA

You need thick shell or you will sand through the edges. Usually, 0.060" shell is adequate. It is easier to inlay the shell while the fretboard is still flat.

As Barry said, you'll need to use thick shell and sand off the excess. I use 0.050" and that works almost fully side to side on a 12" rad, but if I were doing it by hand I'd use 0.060" as he suggested.

For cutting the pocket on a pre-radiused board, I'd recommend running your router/trimmer/grinder on parallel rails above the work so the pocket has a flat bottom and consistent depth from the peak of the board. Parallel rails could be as simple as two pieces of MDF that are the same thickness.

Also, be careful when sanding it level as it's much harder than the wood and it will 'dip' around the shell if you don't use a rigid backer.

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Bob Garrish
Former Canonized Purveyor of Fine CNC Luthier Services

Yes and Yes.

Just don't use Lam shell. You want the soild stuff.

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Joe Beaver
Maker of Sawdust

Here's a few shots of "the beast", used for routing fretboards and even mounted bridges.
I glued up some scrap plexi and threaded some holes in the router base to attach. As you can see it's quite wide. I used the thick plexi to stiffen it, as a first "lighter" attempt flexed too much.

Be sure and use an accurate center line and route flush or slightly above the board at center.

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Paul Bordeaux
http://www.bordeauxinlay.com

You've gotten some good advice, but I'll just add if you have a Williams binding jig, take the donut off & use that....keeps the router level & will soon tell you if you're not going deep enough.

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Dave
Milton, ON

Paul, I have one of those jigs for my Dremel, but without the wings. Good idea! Do you start with a flat fingerboard or radiused?

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A higher purpose for wood.
Rich Smith
Issaquah, WA

Don't let the curvature scare you. I have done a lot of fret boards both with solid and abalam. Both will work. You have to be very accurate on your setting of the abalam but it will curve if you use a little pressure. Solid pearl would be the best choice for your first time.

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John Hall
blues creek guitars
Authorized CF Martin Repair
Co President of ASIA
You Don't know what you don't know until you know it