"Nutcracker Pendant"
(Advanced Intrarsia Project)

by Tom & Kay Benham

Preparation for Bonding Procedure:
One of our secrets for creating quality Intarsia is using a #2 pencil. We mark opposing sides of a strip with a #2 pencil, then grind one marked surface flat on a 180-grit lap. Any remaining pencil marks indicate low spots so we keep grinding until all pencil marks are removed and we have one continuous grind pattern on the surface.
General Bonding Procedure for Two-Part, Five-Minute Epoxy:
· Always clean each bonding surface with alcohol to remove any grease, oil or water . . ..residue caused by handling.
· Carefully measure equal amounts of resin and curing agent and mix thoroughly.
· Allow adequate curing time in a warm place before moving on to the next step.
Drilling Fixture and Spacers:
· Cut two 3" X 3" X 1/8" of plastic for the base and stop piece.
· Cut the stop piece into an "L" shape with each leg 1" wide X 2" long.
· Fasten the "L" shaped stop on top of the base with double-sided tape.
· Make three plastic spacers, ¼" X 1-1/2" X .070" for drilling eyes and nose holes.
· Make two plastic spacers, ¼" X 1-1/2" X .100" for drilling buttonholes on jacket.

Head Assembly:
Step 1: Mark three horizontal lines .070" apart on a piece of pink opal. Mark the center of the middle line for the nose. Make cross marks on the top line for the eyeholes that are .070" from each side of the nose mark.

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Step 2: Chuck a 1mm diamond drill bit into the drill press. Place one .070" spacer against the backstop. Place the pink opal against the spacer and against the left stop. Position the drilling fixture so that the drill bit is centered over the mark for the right eye then clamp the fixture in place. Place a drop of water on the pink opal then drill the hole for the right eye. [TIP: Be sure to cycle the drill bit up and down often to prevent heat buildup and to remove waste material replenishing the water as needed.]

Step 3: Move the pink opal to the right, place two .070" spacers against the left stop, reposition the pink opal against the back spacer and the two spacers against the left stop, then drill the hole for the left eye.

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Step 4: Remove the 1mm drill bit and replace it with a 1-1/2mm diamond drill bit. Remove one of the spacers from the left stop and the spacer from the back stop. Drill the hole for the nose.

Step 5: Using a diamond glass grinder with a ¾" diameter diamond grinding head, grind a 3/8" radius above the eyes on the face for the hat brim.

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Step 5. . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . . Step 6

Step 6: Using the transfer fixture, epoxy a dopstick to the center of a 7/8" square piece of black jade.

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