It all starts on the computer converting patterns to red lines as they are easier to follow. then deciding how many of each and going thru the wood pile to dry fit.

Next covering the wood with clear Duck Brand EasyLiner Adhesive sand the wood and wipe with a tack cloth.

Apply a good coat of 3M Super 77 Multipurpose Adhesive

Cut into individual pieces on the bandsaw.

Sand the back to make sure they are flat

Drill holes where needed.

Now we can start cutting (that is NOT a puzzle) but shows off my $800+ dust collection system.

Next is the hard part.. remove the pattern from the wood (DO NOT WAIT TO LONG.. do it as you go)

Sand Front and Back   

Prepare my MAYO boxes before bath time

Bath Time

restack the pile from top to bottom and dry on shop towels and blow with air compressor. new liner in the maybox and let dry for 2-3 days.

repeat the bath

after 2-3 days sand using paper bags

finially firgure out price

print price tags and attach

box them up

 

 

 

all puzzles are check for choke hasard

The choke test cylinder has an interior diameter of 1.25 inches and a slanted bottom with a depth of 2.25 inches. That’s about the size of a 3-year-old’s throat.