Homemade Wooden Toy Puzzles
Homemade wooden toy puzzles help children as young as 1 year old develop hand-eye coordination. You can complete a simply designed puzzle in one weekend with a scroll saw, a coloring book page as a pattern and a few other inexpensive items. No matter what the little ones in your life are interested in you can create a wooden toy puzzle that will grab their attention and give them that can-do attitude.
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Things You'll Need
- Coloring book
- Colored pencils
- 1/4-inch five-ply plywood
- Table saw
- Rubber cement
- Paintbrush
- Ruler
- 1/8-inch drill bit
- Drill
- .020-inch thick scroll saw blade
- Scroll saw
- Paint scraper
- 100-grit sandpaper
- Tack cloth
- Non-toxic white glue
- Heavy book
- 120-grit sandpaper
- Non-toxic paints or natural wood finishes
Instructions
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1
Select a coloring book page that has a simple design theme. Chose a page with easily recognizable characters, geometric shapes or other design outlines with rounded edges rather than sharp angles.
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2
Color the main shapes on the coloring book page you choose with colored pencils. Choosing different colors for each shape will aide you in recognizing the separate outline cuts needed.
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3
Cut two sheets of 1/4-inch five-ply plywood, equal to the size of the coloring book page, with a table saw.
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4
Spread a thin layer of rubber cement on the back of the coloring book page and the top of one of the pieces of wood with a paintbrush. Press the coloring book page onto the rubber-cement covered wood. Smooth out any creases on the page by running the edge of a ruler over the top of the page on the board.
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5
Place a 1/8-inch drill bit in your drill and drill one starter hole along the cut line of each puzzle piece with the drill.
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6
Place a .020-inch thick scroll saw blade in your scroll saw, position the blade's cutting edge in one of the drilled starter holes and slowly guide the wood under the blade along the first cut line. Lift the blade out of the first cut line and reposition it to cut out the next puzzle pieces in the same manner.
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Remove the cut piece from the scroll saw table and pop the individual puzzle pieces out of the top puzzle frame. Scrape off the paper pattern with a paint scraper. Lightly hand sand the individual puzzle piece edges with a sheet of 100-grit sandpaper. You do not want to decrease the size of the piece but rather only soften the edges. Wipe them with a tack cloth and set them aside.
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8
Scrape off the paper pattern on the top puzzle frame with a paint scraper. Sand the top puzzle frame, including the puzzle piece interior outlines, and the second piece of plywood with 100-grit sandpaper. Wipe the sanding dust off with a tack cloth. Spread a moderate coat of non-toxic white glue on the back of the top puzzle frame, align the outside edges of both puzzle pieces and press them together. Place a heavy book on the top of the two pieces and allow the glue to dry for 24 hours.
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9
Sand the joined wooden puzzle frame with 120-grit sandpaper to remove any excess glue and soften the outside edges. Wipe it with a tack cloth to remove any dust.
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10
Paint, stain or seal the wooden puzzle pieces and puzzle frame with non-toxic paints or natural wood finishes.
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Tips & Warnings
A puzzle frame is recommended for wooden puzzles intended for young children but you can skip the frame or make a standing puzzle for a teenager or adult.
Wear safety glasses while operating drills and saws.
