I'm surprised pottzy hasn't slashed your tires yet C125... it was this blog that started me off on my puzzle venture... though my latest version is 3 different pieces... (more confusion).
In fact I mass produce this one out of 6mm MDF, creating 72 sets per run, and give them away for free, Xmas is a good outlet, (one set is a oopsie)... took about 52 minutes to laser while I could indulge in some cask-o-vino... the rest will be consumed when making up sets to package... might Grinch it and muck up a few sets...
The major cost and hassle is buying and placing them into small baggies.
If your first cut is too short... Take the second cut from the longer end... LBD