Now you need to figure out where you want the shield to go and find a way to get the jig on there with everything lined up. So…put the tiniest speck or two of super glue on the bottom of the shield and place it right on the material (quickly!) You only want the smallest amount just enough to hold it in-place.
Next, put a tiny speck or two of super glue on the bottom of the shield template and gently place down over the shield and onto the knife (like a puzzle piece).
Let it all dry for a few minutes and then go ahead and put the jig together and tighten it down. You don’t have to crank these down...just enough to be snug…especially if you have some of that liner on the insides like mine (somewhat tacky).
Once you are all set…just pull the shield/pin right up!
Now you need to set the depth of your router bit. Since I have extra shields, they worked perfectly for this purpose. You can use anything that is the same thickness as the shield. I plan to make a special piece just for this purpose…but for now this will work. The idea is that you want to set your router bit to just touch the material with the shields (or whatever you are using) in between the router base and the top of the jig. If you do this correctly, the bit will be set to the perfect depth once you remove those shields and start routing.
And off you go! I used a 1/32” router bit to trace the outline of this shield (a little more intricate than some of the others) and then finished it up with a 1/16” bit. It came out perfect and I didn’t have to trim any of the corners or anything like that. You will probably want an exacto knife or micro chisels for the job in the case you do have to trim.
EDIT - I switched it around and started using the 1/16" bit first to get as much routed as I could...then the 1/32" bit to finish up the corners. The new method has been much more successful and I haven't broke any more bits. The idea is that you want to put the 1/32" to work as little as possible because it is very fragile. Also, turn the router off before you pull it out of the jig. If you hit the hardened edge while it is still rotating you will likely break the bit.
Theoretically, I can use the shield/pin tool to now check the fit and still be able to pull the shield out if it is stuck.
So lesson learned for me, I stuck it in too far and it broke off I wouldn’t have to worry about this if I was pinning the shield because I could already have a hole underneath and the ability to poke the shield up from the bottom if I had to.
I got the shield out and then used my 1 oz hammer to gently tap in the real shield…and perfect fit. I set the height of the router bit just a hair short so I didn’t go too deep and it left just a hair of shield above the material line…but it will easily sand down (and I need to buff out the super glue spots anyway). So jigged bone might be an issue using this method!
I am letting the glue dry right now then I’ll finish this up…but even this far I am more than excited to have inlayed my first shield