I’ve picked the eye teeth out of his burr puzzles and some of the others, that are more easily doable and easily converted to my laser cut, MDF laminated method.
This puzzle is a 6 piece puzzle with very basic shape except for one little boy that with a tiny doodad poking out.
From the accompanying diagrams, the original was made out of timber and it should be easily made using a scrollsaw and templates printed from PDF files.
Based on a standard wood thickness, the pieces are cut from a piece that is 4 x 6 of the wood thickness. For tight fit keep dimensions close, and for looser fit pare the thickness.
This is the basic outlay of the 6 pieces,
I have rounded off the corners to make it look pretty-pretty, however, no reason why it can’t be left rough as guts.
For my dimensions, I based it on 6mm MDF
(yes it's hard to read, however, I like a lot of pictures to set the mood and break up reading), with the intention of eventually laminating 2 pieces together to emulate a 12mm thickness (double the above measurements). In the design I allocated dowel alignment holes, however, again that was more for looks rather than necessity.
From SketchUp, it went through Layout to generate a 1:1 dimension PDF which is then imported into CorelDraw. From there, the pieces are laid out with duplicate overlay lines eliminated and then sent to the laser for cutting.
Looks like this puzzle was circa my 5th. Pig Puzzle and I didn’t take too many happy snaps, so all I can offer is a few assembled/disassembled after the fact pieces (galleried) and point yazall to the videos I made,
Ugh! I just looked at the video again and cringed… I should have deleted it and shot again, but left it there to make people realise there’s greater fools than them out there.
As shown in the gallery, each puzzle comes with a “paper solution”.
Unfortunately it comes with a 21 step solution which is a tad hard to fit on a single sheet of paper… well it can but you’d never be able to read it,
and I could never afford Fe$tool if I wasted all my money on laser jet ink to print full sized instructions (21 pages) for each puzzle.
Consequently I’ve included a hidden Easter egg... the solution
points the user to a WEB site that includes the solution documentation. Yet to meet someone that keyed in that sting correctly in under 10 attempts.