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bb040:

you might try a roto zip...

Avery:

There is a trick they used to do for decorative metal inlay where they would make sheet metal stencil, fasten that down and then hit the wood with a litte fork like dubus mounted in a drill press (think really agresive wire brush).

I don't know if this would work for you, but you're talking about such a small area....

If you only hava a couple of these to do, I'd carve them out with an Xacto knife.

DrewKaree:

I think you're talking about a needle scaler

Avery:

No, it definitly spun, that way you could control the depth of cut.

I read about this somewhere, I think in a book on old tools.  I don't know if anybody is doing this sort of thing any more or if they've even done it for the past 50 years.   I just threw it out there in case it gave Ray some flash of inspiration. 

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