Eagle, I think you are a testimony to the fact that there is a Creator. How on earth could a protozoa evolve into something that can produce some of the incredible stuff you come up with? Your accidents look way cooler than my flagship works.
By the way, speaking of a thin kerf, have you considered using one of the slot cutters they sell at Woodcraft that cut the kerf for certain hinges to slide into? The cutters look to be no more than 1/32" thick. I've eyeballed them several times for producing blanks with odd inlays. You can't use it one a tablesaw, but I think they are designed for a router table.
HI Matt, good to see you around again.
Thanks for the compliment but I think there are some that will describe me as still being a protazoa.
The idea of the slot cutter is interesting as I am always looking for a way to make thinner kerfs.If by a slot cutter you are ferring to a blade similar to a biscuit cutter but thinner,then the problem of running the stock through on a bias to create the angle becomes the problem.I think the router base would be in the way if the router were turned a horizontal postion. There is also the problem of depth adjustment.
If I were to go to a thinner kerf I would look into the blades used for cutting guitar necks for the frets.They are .030 but I have seen the cost is around $80.00 each.
The Freud blades work fine, are easier to get and cost a lot less.
I have also looked into "mini table saws" but the cost is ridiculous and the blades are still 1/16th, about the same as the Freud Diablo.
A jig could be used but every time another piece is added to the equation, the opportunity for misalignment enters into the picture.I normally use a Freud 7&1/4" blade which has a kerf of .059 which for all intents and purposes a 1/16th of an inch.
For this blank I wanted a thicker kerf because I was going to add a piece of blackwood between the brass strips.
If you look at the blank pictured note the brass strips are at an angle and there are 4 in a "grouping". The pattern repeats 6 times around the blank.
The original idea was two have 6 pairs of brass strips around the blank(top and bottom) each brass strip is about.018 thick.2 strips would be .036.
I used a CMT blade for this and I really don't remember the kerf but I dimensioned the blackwood filler so that all 3 pieces would dry fit into the kerf. Add Ca and bingo a glue joint!
As for cleaning up the blank I'll let you figure that one out.
Remember I had to repeat the cutting operation 5 more times as this is a hex sided blank.