Custom Truss Rod Cover using Lasered Veneer Inlay

Today, I tried out some veneer inlay using my Xtool D1 Pro laser. My Deering Sierra banjo was a bit plain with no headstock inlay so I designed and made a custom Truss Rod Cover for it.

I used the flatbed scanner on my multi-function printer to get an image of the old truss rod cover then scaled it in LightBurn by measuring the distance between the holes.

After a few tries, I figured out that a laser kerf compensation of 0.004″ turned out to be a pretty good fit.

I used Gorilla Wood glue to laminate three pieces of veneer (walnut + maple from Amazon) with alternating grain at 90 degree angles to get the needed rigidity and thickness and cut the outside shape after it was dry.

I then sanded to 1000 grit and applied my homemade hardwax oil finish (X3 because it was my 3rd attempt at making my own finish because I liked the Rubio Monocoat but didn’t want to pay for it). I’ll do post in the future about how I make it (Candelilla Wax, Carnauba Wax, Tung Oil, Linseed Oil, and Mineral Spirits)

UPDATE: I got a new Nechville Phantom Turtle Hill model from Turtle Hill Banjo Company this week and just did a custom truss rod cover for it also. See photo below.

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