Money Maker

Hands On

MAR/APR 2005
Volume 48/Issue 2

Project Articles
The Sheltered Swing
Turn-Of-The-Century Medicine Cabinet
Puzzle Power

Ask Smitty
Owner’s Gallery
Letters from Owners

Academy Notes
Basic Joinery - The Mortise-And-Tenon
Service Pointers
MARK V Work Table and Carriage

Woodworking Technologies
Stepped Dowels

Safety Lessons I've Learned

What's New
Rip Scale Upgrade Kit, Cabinets, & Lift-Assist

Find A Shopsmith Woodworking Academy Near You

National Woodworking Academy in Dayton, OH

Online Accessory Catalog
Request Printed Accessory Catalog
Online Replacement Parts Catalog

Find A Shopsmith
MARK V Demo Near You

Request MARK V Information Package

Links Worth Visiting
Free Woodworking Tips

Contacting Shopsmith

Copyright 2005.
Shopsmith, Inc.
All Rights Reserved

Puzzle Power

Six easy-to-make toy puzzles for kids aged 3 and up

Cheryl Barnett, a craftswoman from Beavercreek, Ohio designs and makes delightful jigsaw puzzles as gifts...and to donate to church bazaars. Cheryl say that for strength and durability, she uses 1/4" or 3/8" thick high-quality, solid-core plywood and assorted hardwoods for her puzzles. NOTE: When making large quantities of these puzzles for resale, we suggest that you stack a number of workpieces and pad saw multiples simultaneously. Use double-stick tape to hold the pieces together temporarily for cutting. Make your stacks up to 2" thick if you'll be cutting them out with your Scroll Saw ... up to 6" thick if you'll be using your Bandsaw . Once cut, simply separate the parts.

1. Use a Belt Sander or hand-held orbital sander to sand both surfaces of your stock smooth.

2. Make a full-scale pattern from the plans by photocopying or re-drawing them, then attach a plan to the top of each “stack” with rubber cement or re-positionable adhesive from an office supply store.

3. Use your Scroll Saw to cut out the designs on the bold lines (the dotted lines are for detail painting). The Scroll Saw will make much smoother cuts than the Bandsaw...without having to sand the cut lines.

4. If necessary, sand the cut lines of your puzzles, being careful not to distort the interlocking patterns.

5. Starting with the large areas, paint the designs with non-toxic paints or food coloring. TIP: It's best to trace the detail painting lines after you've painted the large areas. A fine-point permanent marker can be used for drawing the details.

6. Coat the finished puzzles with a clear polyurethane varnish.

Suggested retail price: $15 to $20 per set of six

View Plans & Assembly Drawings


Printer Friendly PDF copy of Instructions (499K)