'Bog standard' St George set
Showing chipped pieces
These chips need flattening off
Screw a piece of scrap softwood wood with a 'V' in the end to rest the chess piece against. Pine or deal are good it needs to be softer than the wood you are resting against it to work on. The triangular file is from an automotive store. getting the surface flat needs practice. Use a faceplate with abrasive on where possible. The trick is filing without rounding downward at either end of the surface being filed. This is difficult to avoid doing.
Superglue and wood dust will fill any open cracks, put the glue on and sprinkle the dust. You make the dust on the abrasive face plate on the slowest speed, catch the dust on a sheet of paper held under. I keep dust in little sealed jars in the shop, so a lot can be made at once and then when you're in the middle of a repair you don't have to stop and make it. In this pic, I am holding the patch onto the flattened break, waiting for the glue to set. Below my hand is a scrap of paper with some superglue dropped onto it, a sliver of wood to apply the glue, and the lid of the boxwood dust jar with some boxwood dust in it. Do NOT try to apply this stuff and mend and the same time. Just alternate glue + dust + glue + dust until the hole is well filled and mounded over. Remember that you can turn this glue + dust compound, too, once it has dried, so if it is lumpy and ugly when you first apply it, it doesn't matter. It will turn down and be fine.
See how the dust + glue area is bumpy and rough looking? That's what you want, so you are sure the hole is filled. The piece now goes on the glue chuck and the whole mess (repair piece + glue/dust mend) is turned down.
Another view of mended area.
do the same to the other pieces using ebony or box as appropriate. note the pieces are bigger than needs be and made roughly to shape on a band saw. (take care with fingers)
The knight base was flattened on the face plate as were all the cut pieces. Hence the actual chip to the knight base collar, since there was no finial to dodge, could be flatted on a face plate with sandpaper attached. Also, all the triangular pieces that are mending the chips were flattened on the face plate with sanding paper. Avoiding filing with the triangular file is a goal for me, as the file is difficult.
Finished repairs. See that the boxwood repair is, in fact, noticeable. :(