I've been given an ellipse shaped office table to make. Not so hard, I figure, but the customer wants 2" thick by 1.5" wide solid walnut edging all the way around, with a profile cut into it. If I were to laminate the walnut around it in strips, it wouldn't be such an issue. But the customer wants segments cut out of solid walnut blocks all around the perimeter. Any ideas on how I could make the solid segments so that the joint between the laminate top and the edging is almost seamless?
From contributor R:
You could make an MDF template of the table and template rout the walnut. You would probably have to do it in sections of segments glued together (depends on the size of the table). Then template rout the sections.
Use a 2" spiral bit to do the cutting, taking multiple passes to get to the full depth. Use the same setup to cut your substrate before laminating. You need to be very exact when adjusting the radius of the jig, so the MDF top and edging will fit properly.
Or outsource it to a shop with CNC.