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Dado just a few sticks, then follow your ABCs.
Think twice earlier than you’re taking this puzzle aside. It has six faces, every face has 9 squares and every sq. is lettered. That’s two full alphabets on twelve interlocked elements, all of that are duplicates, however one. Having so many duplicates means every half can go virtually wherever. But due to the letters, every half can go in just one spot.
Make the elements
1. Mill lengthy 3/4″ x 3/4″ blanks which are completely sq..
2. Cut the blanks to size to make the 12 elements (Fig. B), together with extras for check cuts.
3. Set up the noticed and the jig to chop 3/8″ x 3/4″ dadoes.
4. To make Part A, set up the huge spacers and reduce a dado in a 1-1/2″ clean (Photo 1).
5. Switch to the slender spacers and reduce the dadoes in 9 of the 2-1/4″ blanks (Photo 2). Set 5 of those items apart as Parts B.
6. Cut a second dado within the different 4 items to make Parts C (Photo 3).
7. Use one huge spacer to chop huge dadoes within the remaining two blanks to make Parts D (Photo 4).
8. Very evenly sand the perimeters and ends of all 12 elements to create the tiny reveals that outline the squares when the puzzle is assembled.
9. Scribe the center sq. on the surface face of all Parts B and D (Photo 5).
10. Cut v-grooves on all Parts B and D to imitate the sanded reveals (Photo 6).
Assemble the puzzle
1. Make three crosses.
2. Slide the crosses collectively.
3. Install Parts C.
4. Slide in Parts D.
Making this puzzle could also be simpler than fixing it, and when you’re arrange, you may as effectively make multiples. Just assume, give a puzzle to every of your (extremely motivated and inquisitive) youngsters, and the home might be quiet for the primary time in months!
Without letters, this puzzle is fairly straightforward to resolve. Using various kinds of wooden is one approach to approach to jazz it up. Adding numbers makes fixing it fairly a bit tougher. But including 27 completely different characters (26 letters and a query mark) creates the final word problem, particularly if their orientation adjustments on every face. Carving or routing the characters is one choice—the puzzle featured on web page 49 was CNC-routed. You may additionally use stamps or stencils or peel-and-stick characters—a single $5 package deal of half of″ letters and numerals (obtainable at workplace provide shops) permits making 4 alphabet puzzles and two quantity puzzles.
For this puzzle to work correctly, every half should be precisely milled and reduce. If the joints are too tight, the puzzle gained’t go collectively; if the elements match too loosely, it should disintegrate. So, anytime you see a dimension on this story, add the phrase “precisely” earlier than it.
Dadoes lock the elements collectively to kind the dice. A store-made jig makes it straightforward to chop them (Fig. A). This jig consists of a sled with runners, a clamp and a fence. The runners match the tablesaw’s miter slots, so the sled makes perpendicular cuts. The huge fence homes the noticed’s dado set, for security. Stop blocks and spacers exactly place the puzzle elements, so the dadoes are precisely reduce. Like the puzzle elements, the spacers should be exactly reduce.
To arrange the jig, clamp the cease blocks 1-1/8″ from the slot on each side. Then set up the suitable spacers and safe the puzzle half with the toggle clamp. The dadoes have to suit completely, so at all times make further elements and begin by making check cuts. Testing the dado widths and depths is fairly straightforward, as a result of many of the elements go along with lap joints. When the dados match snugly, their widths are appropriate; when the surfaces of the assembled joint are flush, the dado depths are appropriate. That’s it; you’re able to go.
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