Looking to get a little more comfortable with the Techno Router before embarking on a real project, I decided to make a puzzle.
One objective I had in recreating this puzzle was breaking down some of the 2.5 dimension structures to allow the pieces to fit together in interesting ways. For example, a jigsaw puzzle would be very easy to cut on a CNC milling machine, but it takes some extra thought to create a puzzle where the pieces to all come together in different directions.
Setting up the cuts was easy enough. Because of the nature of the puzzle, it was important for the joints to appear seamless. I measured the thickness of my leftover oak and sized the hole in the middle accordingly. I chose, during this process, to use my 1/4 rounded edge router bit to treat the edges of the pieces instead of squaring the inside holes or adding “dog bone” corners.
Cutting the pieces produced no real surprises except that the final piece didn’t make it all the way through. It was enough for me to use the scroll saw for the final 1/32″.
I then got to work routing the edges to see if they could fit together. At this point I realized how useful it is to have a 1/4″ end mill and 1/4″ radius rounded edge hand router bit. As a combination they work really well together.
The pieces still need some sanding and finishing, but it works overall. The one complaint I have about it is that the pieces area little loose when put together. I would work on tightening them up for v2.0.