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The Wooden Castle Puzzle
A great Norm Marshall Toy that’s quick and easy-to-build – and very playable
Here’s a perfect project to put your Shopsmith Scroll Saw through its paces ! We used a combination of ordinary fir plywood (be sure one side of your plywood is “A” grade, without knots, footballs, or similar imperfections), cherry and clear pins…but you can use any combination of stock you like.
Begin by enlarging the drawing (Fig. 1) to full size and numbering the pieces with a pencil. First, cut the backing board (A) and puzzle pieces cutout board (B) from 1/4” fir plywood to 8” x 8-3/4”. Use double-sided tape to tape these two pieces together, then sand their outer edges using your disc sander. Take the backing board (A) and cutout board (B) apart and remove the tape.
Using your full-size castle drawing and carbon (or graphite) paper, carefully transfer the outline of the puzzle pieces to the cutout board (B). Be sure all lines transfer cleanly.
Locate the castle windows and use a 1/8” diameter bit to bore a hole in each one. Insert a .018” scroll saw blade through one of the holes, mount the blade in your scroll saw and cut out the first opening. Repeat for remaining openings. Then follow the puzzle lines and cut out all the pieces, placing each in position in a small box or tray as you cut them.
Once all the puzzle pieces have been cut out, glue and clamp the backing board (A) to the cutout board (B). When the glue has dried thoroughly, sand the assembled backing board and cutout board using a pad or random orbit sander and 220-grit sandpaper.
Next, place the cut-out puzzle pieces into position in this assembly. Remove the (5) cut-out window and door pieces and discard them. Outline these five openings with a black felt-tipped pen, then color in the openings, overlapping the guidelines by at least 1/8”
Finishing the puzzle boards and pieces