Stone Intarsiaby Garry Mahan

Background: This presentation outlines how I make a single-layer multi-framed

cabochon, usually referred to as "intarsia“ cabochon. There are other ways to

accomplish the same goal, and you will end up doing your own thing once you do

enough pieces. I have made the piece shown here using 8-inch diameter diamond

wheels and a diamond-edged lapidary saw. Some lapidaries like to use a flat lap or

even a faceting machine to accomplish this work, but as you will see, that is not

necessary

Materials

1. Epoxy 330. This is the two-part glue that you will use to hold things together. If

you find it difficult to get this glue, different epoxy glue will also work. I like the

330 because it has about a 30-minute set-up time, so if you mess up you can

reposition the pieces. I have also used a 5-minute two-part epoxy for the more

simple intarsias, which worked fine. Most of the epoxy glues dry clear. Make sure

you use one that dries clear.

2. A small piece of scrap window glass if you have one. I use this to mix my Epoxy

on. You can use any smooth surface for this - I just prefer glass.

3. Exacto knife or similar. I use an Exacto knife to mix the Epoxy, but you can use

anything you want. The Exacto knife also works well to clean the dried Epoxy off the

piece of scrap glass, so it is ready for the next glue mixing.

4. Wax paper. This is for laying the pieces on when gluing. The glue will run quite a

bit, so you need something under it that won't stick to your cab, the glue won't run

through it, and is disposable.

5. Acetone. This is for cleaning up the epoxy after each gluing session.

Select your center (focal) cab material and mark out the

shape you want on the slab. Larger cabs mean you need to

use thicker slabs for this step.

Next, trim out your cab:

Grind your cab to shape:

Determine and select your frame construction

Trace center cab onto a piece of paper.

Determine what type of frame you want and draw it around the cab on the paper.

Be creative. The cab shown here will have two frames of the thin framing pieces (a double frame) of contrasting material with a wider outside (final)

frame.

Hunt for the framing material.

Slab inner framing material as necessary. I usually cut the slabs about 1/8" thick and then turn it on its side for the frames.

Locate or slab outer framing material..

Mark out and trim inner frame

Inner frame pieces ready to trim out.

Trim out your inner frame pieces on the trim saw.

Check fit inner frame pieces.

Glue inner frame to cab

Trim/grind off ends of inner frame pieces.

Construct second frame around inner frame.

Glue second frame to inner frame

Trim/grind off edges of second frame

Grind second frame to desired thickness

Construct outer (final) frame

Glue outer (final) frame to second frame

Finish intarsia cab

Since making this cab, I found that it works better to

glue the frame pieces on opposite two sides, then grind

off followed by the other two sides (this presentation

showed gluing adjacent sides rather than opposite

sides).