Puzzle Box
After showing a couple of toys built from wood scraps during a SAWS zoom meeting, a member expressed interest in plans for the same.
In response, I assembled this article to display photographs and provide templates with brief instructions for anyone wishing to duplicate my creation.
This project should be appropriate for children aged three years and older.
Print the patterns at 100%; dimensions are displayed in the instructions. Use spray adhesive to attach printed patterns to scraps of wood leftover from previous projects.
Materials
Four 1/4 inch plywood panels that form the two outside front/back plates and two shape cut-out internal plates,
Eight 3/4 x 1/2 inch pieces that form the frames,
Twenty-four 3/8 inch thick shape pieces (use solid hardwood for best appearance).
Hardware
Two hinges
One hasp
The box shown in the photographs measures 6 3/4” x 8 3/4” x 1 1/2 “. For best results, cut the individual shapes and shape openings with a scroll saw using #3 or #4 blades. The width of these blades and the technique of cutting on the correct side of the shape lines, to ensure the panel openings are slightly larger than the patterns and the shape pieces are slightly smaller than the patterns, will result in a good fit.
Instructions
Using the templates, cut the four plywood panels oversize.
Attach the cutout templates to two of the plywood pieces and cutout the shape openings using a scroll saw; cut on the outside of the lines defining the pieces to ensure the openings are slightly larger that the pieces that will be dropped into the cutouts.
Glue the plywood internal panels to the outside front and back panels with the good sides facing outward. NOTE: cut the centre for the donut piece (cut inside the line defining this piece) and carefully glue it to the background in the centre of the cutout that receives the donut shape (this ensures the circular piece cannot be placed in the opening intended for the donut).
Cut the resultant pair of finished panel sets to finished size along the perimeter lines on the templates.
Using the cutout templates (with a scroll saw for best accuracy and smoother edges than left by a bandsaw) cut the shapes from 3/8 inch thick hardwood; cut on the inside of the lines to ensure the shapes are slightly smaller than the openings in the plywood panels. Lightly sand the edges round (this causes the pieces to fall out more easily, when the box is opened, and makes them feel better when handling).
Cut a 5/16 inch deep groove into the 3/4 inch side of the frame pieces, sized to fit the glued up plywood panels. Position the groove such that the top of the shape pieces will rest slightly lower (at least 1/32 inch) than the top of the frame after assembly; this will allow the box to close without interference (too much space will allow the pieces to fall out of place after closure).
Cut the frame pieces to length to fit the panels (use mitred corners) allowing space for movement due to humidity effects. The lengths should be 6 3/4 and 8 3/4 inches (allowing 1/8 inch for panel movement), but verify using your panels before cutting.
Glue the frame pieces together.
Cut slots for splines in all mitred corners and glue splines in place. This will ensure the frame doesn’t easily break due to rough handling by children.
Sand all pieces.
Inset/attach the hinges, attach the latch pieces and apply finish.
Place the pieces into the appropriate positions.
Lift both sides simultaneously, closing the box before pieces begin to fall out of place.
Note that the pieces are intentionally thicker than the panel they fit into, to ensure they always fall out of place when the box is opened.
Templates
A PDF of all the templates can be downloaded here.