The process for constructing the intarsia was a microcosm of the overall construction project. After the layout was complete, we made a jigsaw puzzle, laying out each piece of the pattern on the wood and cutting it out. In the middle ages, these types of cuts on quarter-inch thick would would likely have been done with a thin, narrow bladed saw similar to a modern coping saw. Because of time constraints, we substituted a modern scroll saw.
We then did a dry assembly on the surface of the stool. Because the inlay for the field on the badge was out of the same maple as the gross construction of the stool the badge tended to disappear, leaving just a stripe of cherry wood when viewed from a distance. To remedy this, we added a narrow strip of walnut around the perimeter of the badge, which made it stand out to great effect.
The next step was to carefully excavate the cavity where we were going to install the device. In the middle ages, this cavity would likely have been chopped with a hand-chisel. Once again, in the interests of saving time, used a modern router to handle the bulk removal of material, only switching to hand-chisels to finish the job. We removed 3/16" of wood in the size and shape of the shield to accommodate the device.
Because medieval glues, made from fish or animal hide, require heating and have long set and cleanup times, we elected to substitute a modern yellow glue to secure the intarsia to the cavity. When assembled, this left the device standing proud 1/16" of an inch, and allowed us to sand it down flush with the surface, with no danger of removing too much material.