Making Puzzle Boxes

Cut your wood block with a bandsaw to the size and shape you want the box to be. Begin with a solid block of hardwood. This project requires you to make a small, tight circle for the keys, so a 1/16-in. blade is recommended.

Cut a thin slice (approximately 1/8-in.) using the bandsaw off the bottom of the box you have shaped, and put it aside until you have cut all of the pieces for the remainder of the box. Cutting the bottom of the box off first will allow you to cut the key holes without cutting into the bottom of the box.

Cut out the first key from the box with a bandsaw. The key is a panel in the box that will be cut out now and then replaced when the box is finished. The keys--or secret panels--need to be located and removed in order to open the box. Cut out the first key on the left hand side of the box. This is best done in a bulb shape on the left hand side of the box. The key begins as a straight line from the bottom and then becomes a light bulb shape at the top. The light bulb shape cuts into the top of the box. The circular part of the light bulb shape must be larger than the neck of the light bulb shape key in order for the box to not fall apart.

Cut out a second key with your bandsaw across the top right side of the box. This cut also should be bulb-shaped and should go across the top of the lid horizontally. This cut should not extend into the side of the box. It is a cut in the top of the box that begins straight and ends in a bulb shape. This key will be situated beside the rectangular opening in the center of the box.

Cut out a piece for the center of the box. This piece should be rectangular and should meet with both key holes. Completely cut this piece out and then gently reset on top of the box. This piece forms the main opening of the puzzle box and allows you to put trinkets and treasures into the box. It is necessary to cut this piece out now so when you remove the keys to open the puzzle box you will have a top opening to remove to access what is inside. Once you cut the rectangular piece, place it back on top of the box right before reinserting the two keys.

Glue the bottom of the box (from Step 2) back on. You should now have a complete bottom with nothing cut out of it. Unlike the top of the box, there is no need to have a cutout or key hole in the bottom of the box.

Sand all of the pieces for a smooth, finished look. To give your box a more finished look, sand each piece as you are making the box.

Reinsert the two keys in order to lock the puzzle box. You will now have a completed box

Remove the keys and the top of the box in to reopen the puzzle.