Instructions
Drawing the Puzzle (Part 1)
****Important make a copy of this before proceeding to Part 2 |
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MAKING COMPONENTS AND MOVING THE PIECES OF THE THREE PIECE PUZZLE
It is necessary to turn each piece of the puzzle into a component prior to moving them. If this step is not done pieces will be stuck to one another when they touch, this is known as sticky geometry. One the pieces are turned into components use the move tool rotate the pieces to the proper orientation. Make sure you use the move tool, and not the rotate tool. Also make sure that you only rotate the blocks in 90 degree increments. failure to do this will cause you a big headache. |
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MARKING THE THREE PIECES OF THE PUZZLE
You will need to make three pieces that are 1 5/8" wide and 4" long, out of 3/4" stock. This puzzle could be made out of a variety of materials. Pine is one of the easiest and cheapest material for this project. Throughout this project you will be using a variety of tools and machines. Always wear your safety glasses and follow all safety rules that apply to you are doing. Also remember to always cut on the scrap side of the line when possible. |
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CUTTING THE THREE PIECES WITH THE SCROLL SAW
This video shows the process of making a simple cross cut with a scroll saw. You may want to watch the scroll saw safety video prior to this step. Always read your owners manual and follow all safety procedures. |
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LAYING OUT THE RECTANGULAR OPENING ON ALL THREE PIECES
Please watch this video to help you layout your lines correctly. Remember a mistake here will result in a bad puzzle. Take you time and be as accurate as possible. You will Need Pencil Square Ruler Three blocks of wood |
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LAYING OUT THE SMALL SIDE OPENINGS ON BLOCK TWO AND THREE.
This video shows you how to layout the small opening in the second and third pieces of the puzzle. Again be as accurate as possible. You will Need Pencil Ruler Square Two of the blocks from the last step |
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USING THE DRILL PRESS
The Drill Press is a great machine for a wood and metal shop. However it does have spinning parts which can make it a dangerous machine. You should watch the Drill Press Safety video prior to using this machine. This machine has been set up with a back stop which prevents a piece from spinning if does get loose. You may wish to clamp the work piece down pending on user experience. Follow your machines user manual. |
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USING THE SCROLL SAW
In this step you will use the scroll saw to cut out the shapes. Make sure that you follow your lines. Keep the blade on the scrap side of the line which in this case is piece in the middle. Crossing that line will ruin your puzzle. If it looks like you are going to go across the line turn the piece in the direction that steers the blade in the correct direction. Do Not push sideways on the blade that will ruin the blade and possible break it. Use the holes that yo drilled in the last step when making the 90 degree turns. |
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USING THE MORTISER
The mortiser used in this video is an attachment to a standard drill press. Mortisers are used to drill a square hole, this is done by using a hollow square chisel with an auger in the middle. As the chisel is forced through the wood the auger pulls the wood chips up and out the front opening. |
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FILING THE INSIDE OF THE PIECES
This video shows how to file the insides of the three pieces. File carefully as you only want the opening to be just big enough that a piece easily slides through the opening. Use these techniques reduce the amount of tare out that could occur. Remember not to clamp the vise to tight as this could leave marks in the wood. |
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USING THE DISC SANDER
A disk sander is a quick way to sand down the ends of your puzzle pieces. Remember to keep your fingers away from the disk. As always make sure to read and understand your users manual prior to using the machine. |
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PUTTING ON THE CHAMPHER
A champher is a 45 degree bevel that removes the sharp 90 degree corner. This is commonly done in woodworking for a couple of reasons. A sharp 90 degree corner can cut or injure someone rather easily, by removing the sharp corner the piece becomes safer. A 90 degree be dented easily, the champher helps reduce damage to the piece. |
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FINISHING THE THREE PUZZLE
A little light sanding and clean up will give your puzzle the finished look. Adding your initials with the stamps makes it yours. |