I have made similar bears to this one, but I was not happy with the design. The keys were very near the same size and shape, and they did not lock the puzzle together very well. I change the design so the keys would be distinctly different shapes and locked together well. It looks a bit odd, but it works great.
The bear puzzle is cut from a 1x12 pine board using a scroll saw. The surfaces of the board are sanded before the pattern is applied to remove any defects and to provide a smooth surface for the wood to slide on the saw table.
I apply 3M ScotchBlue tape to the wood before adding the pattern. The tape is easy to remove and helps prevent burning and lets me remove the pattern without using toxic solvents. If the patterns are glued directly to the wood you have to do something to get the glue residue off. 3M ScotchBlue painters tape does not leave any residue and it sticks very well.
I print my patterns with a laser printer and apply 3M spray adhesive to the back of the paper. After the pattern is applied to the wood I cut out the puzzle with a scroll saw.
Using good quality blades very little sanding is required. Usually, all I need to do is smooth the fuzzies off the edges. I do most of this sanding with a Klingspor sanding mop mounted in a Harbor Freight drill press.
This puzzle is finished with a mixture of beeswax, mineral oil, and Vitamin E. I also make puzzles with no finished and some that are painted.
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Click here to see my other puzzles.
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