Tools & Materials

• Fretsaw (https://en.wikipedia.org/wiki/Fretsaw)
• Fretsaw blades
• Plywood (for fretsaw)
• Printer/printed image on paper
• Sandpaper
• Clear Varnish (optional)
• Cost 20 – 40 $

Workplace preparation

Prepare a clear space for the fretsaw use. We have used the table in our kitchen.

Place some cover over the table to avoid damaging the surface (blanket or plastic cover).

Prepare the fretsaw: insert the blade, check if has correct blade tension (a video tutorial here: https://www.youtube.com/watch?v=7Xt6YPxEUgk)

Choose and print the puzzle image

Measure the plywood, the dimensions are used to edit and print the image.

We have picked a Mario picture

wooden puzzle image

Trace the puzzle cutouts (shape of the pieces)

To help the design process you can draw grid lines.

Make the shapes irregular and also it would help for the puzzle stability to have the shapes similar with a real puzzle.

wooden puzzle design shapes 1

wooden puzzle design shapes 2

Attach the image to the plywood

On the plywood face, attach the image (on the back you should see the pieces drawings)

We have used silicone glue to stick the image to the plywood.

wooden puzzle attach image

Cut the puzzle pieces (parent help if needed)

wooden puzzle cut pieces

Don’t give up if the blade breaks 🙂

wooden puzzle blade fail

After cutting all the pieces, the puzzle is almost done.

wooden puzzle pieces

Finish the pieces using sandpaper – remove the hard edges.

Varnish the puzzle

The varnish will provide some extra durability to your puzzle and it will surely look better.

We have use a varnishing spray.

Extra care!!! Before spraying, place the puzzle on some large piece of paper or cardboard, the varnish can damage or attach permanently to the surface.

wooden puzzle varnish