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How to Make a Wood Toy Puzzle

One of the best ways to engage children and help their concentration, memory and spatial reasoning is to get them working with puzzles. There are thousands of cardboard puzzles available through drugstores, toy stores and the Internet. But these puzzles often can be flimsy and susceptible to damage from food spills. One solution is to make your own puzzle from wood. These puzzles are sturdy and long-lasting, and they carry sentimental value for the maker and child. Not just for your own child, wooden toy puzzles can be a creative hobby and could be sold for profit, too.

Things You'll Need

Design pattern
3/4-inch pine or basswood
Sealer/primer
Acrylic paint
Paint pens (optional)
Fine sandpaper
Spray-on adhesive
Paintbrush
Power sander (optional)
Scroll saw or coping saw with No. 9-size saw blade

Instructions

How to Make a Wooden Puzzle
- 1
  Obtain your pattern. You can draw a pattern freehand on a piece of paper, in any shape you like. You might need to draw the pattern more than once to size it correctly. Place your prospective outline(s) on top of the wood to make sure it will fit. There should be a couple inches of clearance on all sides of the pattern for cutting.
- 2
  Draw the puzzle pieces on the inside of your outline. Make them large and easy to cut. You can also obtain patterns online. Cut out your pattern, leaving 1/4-inch to 1/2-inch of excess paper all the way around your outline.
- 3
  Sand both sides of the wood with sandpaper or a power sander.
- 4
  Apply a layer of packing tape to one side of the wood--the side you will later put the pattern on for cutting. The packing tape will give the wood some lubrication for the cutting.
- 5
  Apply the pattern to the packing tape with the spray-on adhesive.
- 6
  Saw the outline of your pattern. Saw the individual pieces by following the guidelines you drew inside of your outline. Remove the pattern and the packing tape.
- 7
  Sand the pieces again, with fine sandpaper, to remove any imperfections. Make sure the wood is very smooth. Apply the sealer or primer to the wood. Wait until it is completely dry.
- 8
  Apply one coat of paint. Wait for it to dry, then apply another coat of paint.
- 9
  Use paint pen(s) to apply any details to your design. For example, if you design an animal, you can use the pens to draw eyes. If you design a train or a barn, you can use the pens to draw windows and doors.

Wooden Toys