Wow! Loads of information to work through.
I will say that I am using the thicker material at a 45 degree angle on purpose. Being new to this method I felt it would be easier to use 1/8" material with a 1/8" blade as a learning process.
And I am indeed using a thick CA. I am not seeing any issues with bonding using this glue. I don't understand what you mean by "...there is no fill of your kerf when cut...". Yes, I know what a kerf is. But what do you mean by fill? The inlay touches side to side with a thin layer of thick CA. Even though I am clamping it, as per your suggestion above about allowing room for the glue, I may not actually need to. The inlay slides in smoothly with no play once it is in the kerf. I just felt maybe it should fit more snugly but to have room for the glue, it's probably right where it should be.
I will certainly take your words to heart and play around some more. I had not thought of using the lathe to drill. I will need to get some new jaws for my Nova chuck as I only have what came with them and I don't think they will do well for this.
Thank to very much for taking the time to share your knowledge! Now to practice, a lot!!! Lol
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