First step was to make a jig to cut the shell. Inspired by the stew mac design + what Larry used in the DVD + many web searches I came up with this.

It hooks up to my shop vac, and has screens to prevent the good stuff from getting sucked in.



You can see my first attempt at inlay in the background of that last photo - it's in a piece of MDF I made to test peghead designs.
If you're interested, here's my blog post which describes how I built and used this thing.
Joe Dz