Thanks!  I'm thinking I will just need to jump in and try this next time I can get in the shop.  Appreciate the extra pictures and diagrams.   

BB1, I was inspired by Lazyman to make this puzzle a while back on LJ's. I based mine of the puzzle theme rather than a kitchen utensil.

Don't know whether you can operate SketchUp (free version available on the WEB) loaded from link below, or just printing out PDFs, all the files I used are available at,
   this cloud storage.
There should be a movie of the SketchUp animation.   I based my design on laminating 4 layerrs of 6mm MDF cut on the laser, however, the PDF's should give cutting templates to minimise glueing. 

If your first cut is too short... Take the second cut from the longer end... LBD