Fifteen years ago I rebuilt my house and had new hardwood floors installed. They are red oak (3/4?) over a plywood (3/4?) subfloor. Well it?s time to have them refinished, but before I do, I? d like to build a medallion and inlay it into an area of my floor.
I may do more than one, but the first one I am considering would be for an area about 30? square. The inlay material is not yet decided, but will probably be maple, cherry and walnut. Perhaps some others yet to be n amed (purple heart). I haven?t yet decided on the pattern (researc hing now) nor the shape (round, square, rectangle, diamond), but here is th e technique I am considering:
- Freeze the dimensions and shape.
- Create a template for the actual inlay size, probably from MDF.
- Use a router and the template to cut the outline of the inlay into the floor as deep as the red oak (about 3/4?) and remove the red oak i n the field of the inlay.
- Measure the height if the existing floor above the subfloor and determ ine the maximum value.
- Secure a quality, flat piece of 3/8? plywood a little larger t han the template opening and measure its thickness.
- Plane the hardwood for the inlay to a thickness (around 3/8?) such that when it?s glued to the 3/8? plywood, it will be j ust proud of the existing floor.
- Cut the pieces for the inlay and glue them to the plywood. I intend t hat the glue cover the whole surface of the plywood.
- Use the template and router to trim the inlay assembly to the size of the opening I routed in the floor.
- Coat the subfloor with glue and then insert the inlay into the floor o pening. Apply weight until the glue dries.
- If all goes as planned, the inlay should be just proud of the existin g floor and the floor finishing people can hit the area with a final sandin g to make it flush before the new finish is applied.
I may be making a mistake thinking than wood expansion will not be an issue because I am gluing onto plywood and then gluing the plywood onto more ply wood. I would like to hear from others whether they would be comfortable w ith this technique or whether they see problems.
Thanks, Bill Leonhardt