Making Wooden Jigsaw Puzzles: Creating Heirlooms from Photos by Charlie Ross

By Charlie Ross

Puzzle maker Charlie Ross personalizes puzzle making by means of sharing with the reader assorted the right way to upload their very own inventive contact to this renowned scroll observed woodworking undertaking. From studying to transform a favourite electronic picture, artwork print or different photo onto a wood jigsaw puzzle, to learning his 3 puzzle-making tools of strip slicing, stair-step slicing, and unfastened shape slicing, readers, no matter if newbie or skilled, can circulation at their very own speed in training each one process. Ross additionally comprises designs for brain-busting puzzles with imbedded hidden items, no corners, and different shrewdpermanent techniques.


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I look for well-built carcases and face frames. The bottoms, sides, and backs of the cabinets should be in good condition and anchored to one another solidly. Adjustable shelves should work. I also check that face frames are firmly attached to the cabinet carcases, or can be reattached easily, and that the face-frame joinery is flush and secure. A set of kitchen cabinets, of course, is made up of a number of smaller units that are assembled when the kitchen is installed. If there are gaps between the face frames on adjoining cabinets, I usually can pull the cabinets together with drywall screws.

When I’m cutting with a dado blade, it helps to have a throat plate, the removable portion of the saw table that sits around the blade, for the 1⁄4-in. dado. The throat plate supports the plywood’s fragile veneer, reducing the risk of tearout. The dado should go about halfway through the 3⁄4-in. plywood. To adjust the The inside edge of the dado should be barely depth of the dado, I place a scrap of the ply- visible. wood flat on the saw table against the blade The mating part to this groove is the (see the top photo above).

On narrow cases, I use a press fit because short pieces are too stiff to flex. To trim the overhanging edging flush with the 3⁄4-in. plywood, I use a router with a trimming bit (see the photo on the facing page). Making several passes from right to left helps avoid splitting. The trimmer leaves Hardwood edging covers the exposed plies on the front of the case. Traditional cabinets would have a face frame, but the cases featured here are frameless. Although full-overlay doors cover the cases when closed, opening doors reveals the edges of the case, so edging is required.

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