Step 1: Making the metal blank
Step 2: Danny Garcia at the controls of the Shop Bot table cnc table router
By using a 3d modeling software available at Techshop and Danny's Jedi like mastery of it, we come up with a file that gives us a nearly finished piece right off the router.
The basics of gluing up the blank are not covered here, but planing of the wood and the glue surfaces was done in our wood shop, and then glued and clamped to make a square blank large enough to cut both pieces from. The wood we used wash Ash, chosen by me for the blonde color.