The Woodshop Shed

adventures in woodworking and home maintenance, from my shop in an oversized backyard shed

April 2020
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Hexy Jigsaw Puzzle.

Furnished content.
(from Lumberjocks.com)


Hexy Jigsaw Puzzle.Boys and Girls,
This project was inspired by one of Steve Good's scroll saw patterns.Some of the pictures contain small nude silhouettes so if you are easily offended toughen up Nancy!For once SketchUp was given the cold shoulder and I went straight into CorelDraw. Imported Steve's PDF and proceeded to colourise the pattern,

Colourisation in the above diagram controls the cutting order won't bore you with why, unless someone asks, and then I can ignore.For previous puzzles out of MDF, I used to colour the bottom side with a texta pen (Sharpie to all you Philistines) to differentiate between the pieces' sides,

however, I thought of engraving something on each piece to indicate the downside. Deliberately avoiding the alphabet, as not everyone speaks Australian, or numbers, as not everyone can count, I chose to use silhouettes, as there are a lot of perves. I made use of these silhouettes (that I intend to include in a future post),
Off to the laser and finished up with a 3 layer design,
(for you eagle eyes the above pictures were taken after the engraving on the middle piece was filled
).
The bottom layer was the pattern, middle the base and the top layer the puzzle.For design #1, alignment dowels were glued into place,

as the outer pieces were not to be glued to the dowel, this permitted the dowels to be buffed permitting smoother fit.The bottom layer was flocked,
There was a change of pace and the silhouettes were engraved and filled prior to cutting to facilitate sanding,
For the prudish, the pieces were then buffed and test assembled,

and as an afterthought for the more adventurous, assemble with the bottom side indicators facing up (which became the standard design),
For design #2, the bottom pattern layer was replaced by a laminated paper design of the pattern that can be used as a guide and then stowed under the puzzle for storage,
Design #1, uses flock on the bottom layer to prevent slippage,

however, when the pattern layer is removed it props on the 4 dowels,
Wasn't happy with that and that's the reason for design #2 which had rubber pads on the base,
These are the available options.

  1. Prudent operator.
  2. 3 layered option.
  3. The not so sensitive user.
I was asked for a conservative pussy (not my word) theme. This is how the lamination is fed into the laser,

And this is how it comes out of production. Can be used in either mode (pattern up or down),
The two #2 designs in the revealing configuration,
One of the benefits of the laser, when you make a mistake and detect it too late, you can redo single pieces and be assured it will fit in place. This piece had one of the silhouettes too close to the edge,

For all you musing about the perforated base, you need muse no more. When using without the pattern (up or down side), if the piece is in the wrong place (usually discovered near completion), because of the small kerf of the cut, it would be difficult to pry out a piece so it can be poked out from under the base through an appropriate hole,
I didn't consider laying the puzzle flat was a great show piece, so SketchUp came to the rescue to design a stand,

and off to CorelDraw for laser layout,
Stained, buffed and glued up (CA) ready for use,
Two sizes of stands were produces as the design #1 was 3mm thicker than #2 and I didn't want slop,

Furthermore the stand provides a rest for the pattern while cheating assembly,
Had a friend recovering from a hernia operation so I gave him a girlie version while recovering. His 5 yo daughter commandeered it. She was going to take it for show and tell, which we both thought might be inappropriate, so I designed an animal based version,
It was a hit begrudgingly I grinched on about 20 orders.My copies now assist in filling my puzzle display cabinet,
Phew, that was longer than my anticipated few word post, but with home confinement, I had time to type.I prefer to shy from construction/build videos as I only have two hands and none spare to hold the camera, however, for anyone wanting to see it in operation, I made a video of its use... so maybe you should watch that before you waste time reading this post.


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My Hackberry bowl

Furnished content.
(from Lumberjocks.com)


My Hackberry bowlThis was a piece of trunk of Hackberry, I got it turned and finished it with 2 coats of Aqua Coat sanding sealer and 3 coats of Aqua Coat Lacquer top coat.



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Marquetry Foolishness ... another shop bench

Furnished content.
(from Lumberjocks.com)


Marquetry Foolishness ... another shop benchIn these times we need something to smile about. This is another marquetry folly of mine in the form of a work desk for the marquetry room in my shop. It features marquetry bouquets and parquetry from the work of Jean Henri Reisener.
More importantly it will make me smile every time I go into the room.Thanks for looking,Stay well everyone!



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