"Nutcracker Pendant"
(Advanced Intrarsia Project)

by Tom & Kay Benham

Jacket Assembly:
Step 46: Cut two pieces of red coral for the jacket sides. Grind left and top sides flat and perpendicular to one another.

Step 47: Chuck the 1-1/2 mm diamond drill bit in the drill press.

Step 48: Place the top left corner of one red coral piece in the drilling fixture against back stop and left stop. Clamp the drilling fixture so the drill bit is centered .140" from the backstop and .400" from the left stop. Drill the first buttonhole in the red coral.

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48 . . . . . . . . . . . . . . . . ... .. . . . . . . . . . . . . . . . 50

Step 49: Move the red coral to the right, place a .100" spacer against the left stop, and push the red coral back to the left against the spacer and drill the second buttonhole.

Step 50: Move the red coral to the right, place another .100" spacer against the first spacer then push the red coral back to the left against both spacers and drill the third buttonhole.

Step 51: Repeat Steps 48 - 50 for the second red coral jacket piece.

Step 52: Apply a small piece of double-sided tape to one side of the red coral. Use two .060" twist drill bits to align the buttonholes of both pieces of red coral. Press together firmly.

Step 53: Grind the side closest to the buttonholes flat, then grind a 45 degree angle at the top left corner for the beard.

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53A . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . 53B

Step 54: Take the two pieces of red coral apart.

Step 55: Cut two small triangles of black jade. Grind the hypotenuse of each triangle flat. Epoxy this side of each beard piece to the ground angle on each jacket piece.

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Step 56: Grind the top surface flat. Re-assemble and re-align the red coral pieces with double-sided tape

Step 57: Grind the long side (center seam) of the red coral jacket pieces so that the protruding beard pieces are even with the red coral. Using the 90 degree grinding guide, grind the top edge flat.

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57A . . . . . . . . . . . . . . . . ... .. . . . . . . . . . . . . . . . 57B

Step 58: Take the two pieces of red coral apart. Epoxy the two halves of the jacket pieces so that the beard and buttonholes are aligned.

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58 . . . . . . . . . . . . . . . . ... .. . . . . . . . . . . . . . . . 59

Step 59: Cut two pieces of yellow onyx .150" X .150" X 1/2" long for the buttons. Epoxy the end of each piece to a dopstick.

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60A . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . 60B

Step 60: Grind a piece of yellow onyx into a cylinder. Check the diameter often with a caliper to sneak up on the actual buttonhole size to ensure a snug fit. Repeat for the second piece.

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