For a couple of the younger kids on my Christmas gift list this year, I made name puzzles with my X-Carve.
The puzzles are made out of Baltic birch plywood; the letters are 1/4″ thick and the base is 1/2″ thick.
I cut out the letters of the name (and some additional puzzle pieces) with a very small bit (1/32″), so when the letters are placed in the puzzle, they have a total of 1/16″ of play. This is probably the maximum allowable play before the pieces start to feel loose.
These letters were from a proof-of-concept puzzle that I didn’t end up finishing, but you get the idea.
I carved the puzzle piece insets 1/8″ deep and rounded the corners of the base.
On one of the puzzles, I also included the logos of the Minnesota Wild and the Minnesota Twins. I gave the Wild logo some depth by carving out one of the areas that was a single color. This made it easier to paint too.
After painting the pieces, I gave them and the bases a couple of coats of clear enamel.
Which piece goes where???
I hope that the kids like these for now, and when they get older, they can glue the pieces in place and use these as wall or door hangings.