Inlay Calculator — Decorative Wood Inlay

Rout the recess slightly SHALLOWER than the inlay thickness — not deeper. A common rule is to cut the groove about 0.4mm (1/64in) less than the inlay/banding thickness so it sits a touch proud, then scrape or sand it flush after the glue has cured. This calculator subtracts a 0.4mm proud margin by default, so a 1.5mm inlay gives a ~1.1mm recess. If you rout the recess deeper than the inlay the inlay sinks below the surface and can never be sanded flush. True sawn veneer is around 0.6mm thick; constructional/thick veneer runs 1-2mm, and solid-wood inlays 3-6mm. A router with a depth stop ensures a consistent recess depth.

A small router or Dremel with a straight bit for recesses, a sharp craft knife for marking lines, and a chisel for cleaning up corners. For fine line inlays, a scratch stock or inlay routing kit is invaluable.

PVA or hide glue works well for most inlays. Apply glue to the recess, press the inlay in, and clamp with a flat caul. For very thin veneers, contact adhesive or iron-on veneer methods work well.