How to Cut Out Wood Puzzles
- 1). Transfer the puzzle shapes to the sanded wood by spraying a light coat of spray adhesive to the wood. Let it dry until tacky and affix the pattern. If you prefer to avoid adhesive, place a paper replica of each shape on the wood and trace around each shape with a pencil.
- 2). Put on safety goggles.
- 3). Clamp the wood on top of a piece of scrap wood.
- 4). Drill a small hole directly on the pencil line of each area where a cutting line needs to begin. If the puzzle contains separate pieces, drill on the line of each piece. If all pieces are connected, one hole should be sufficient. The drill bit should be slightly larger than the size of the blade you will use to cut out the pieces. Remove the scrap wood.
- 5). Thread the blade of a scroll saw through the drill hole. Adjust the tension so the blade appears to form a black line rather than a blurry line when running.
- 6). Power up the saw and follow the pattern lines as slowly and closely as possible, keeping the wood moving at all times to avoid friction burns. Do not force the wood through the blade, allow it to progress naturally. Keep your fingers out of the way as you guide the wood along. If you must reverse the cut, do it while the machine is running. If possible, do not shut the saw off until you have reached the end of a cutting line.
- 7). Remove the saw blade from the project. Lightly sand the edges, if necessary.
- 8). Pull the pattern off the wood. If necessary, loosen the adhesive with an iron or hair dryer, or rub it with rubbing alcohol or another solvent. As a last resort, sand it off. If you used pencil lines, erase them.
- 9). Glue the puzzle frame to a piece of wood of an identical size. Clamp them together until dry. Remove the clamps and insert the puzzle pieces.
