Making a puzzle is a very fun pastime and brain training. Making your own puzzle is an even more exciting challenge that gives a whole other dimension to the project! Homemade puzzles are also heartfelt gifts that you can personalize for those you care about most. Depending on the tools at your disposal, you can obtain puzzles of simple cardboard or wood, cutting the pieces with a jigsaw. Either way, your friends and family will love putting together the handcrafted puzzle you created for them!
Steps
Part 1 of 2: Prepare the Image for the Puzzle
Step 1. Choose a design or image
You can print a photograph to use as a puzzle image, or you can make a drawing, use a postcard, poster, or other printed image. If you have decided to use a photograph, choose a high resolution one, whose dimensions correspond to those of the puzzle you want to make. Print it out on your computer or go to a photo shop to get the size and quality you want. Alternatively, you can use whichever technique you prefer and draw or paint the subject directly onto paper.
You can also develop the image on the computer and then print it as if it were a photograph
Step 2. Choose the back of the puzzle
Plywood is certainly the most used and resistant material, but it is only suitable if you have a hacksaw available and are able to use it. The cropping stage is a delicate process that requires experience. You can also opt for a good quality card stock - it's much easier to cut and scissors are enough. Cardstock for craft projects are available at fine art stores.
- The ideal thickness for the back of a puzzle is about 3mm, regardless of whether it is cardboard or plywood.
- Look for a material whose dimensions are similar to the image, to avoid having a lot of waste and scrap pieces.
- You can use cardstock from an old box and stick it on the back of the design, but make sure it's clean, undamaged, and flat. Thin cartons like cereal boxes are fine for simple puzzles, but a thicker material is usually preferred.
Step 3. Get all the tools you need
In addition to the image and support material, you will need glue, spray lacquer, ruler and a pencil. If you have chosen to use cardstock, you will also need to get a sharp pair of scissors or a utility knife. If you have opted for plywood, you will need to have a jigsaw (a hand saw for making intricate shapes) or a winding saw (an electric or foot operated tool that is perfect for complex curves).
- Liquid and spray vinyl glue are best for making a puzzle because they are suitable for many uses and won't damage photographs.
- If you've decided to use a photo as your puzzle image, then get a hairspray that won't spoil it.
Step 4. Attach the subject to the support material
Lay the cardstock or plywood on a sheet of parchment paper or wax paper to protect the surface underneath and make sure the best side is facing down. Spray the material with glue or spread it with a brush to create an even layer. Attach the image to the sticker and use your fingers to move it until it is perfectly centered and straight. Apply even pressure across the entire image using an old credit card or roller; make sure that the design fits snugly and eliminate any air bubbles.
Wait for the glue to dry. Different types of adhesive have different drying times, but if possible you should wait several hours
Step 5. Cover the design with lacquer
Take the puzzle to a well-ventilated area, place it on a sheet of parchment or wax paper, and then spray it with the lacquer, on the side of the image. Also in this case, check the drying times shown on the package and proceed accordingly.
Part 2 of 2: Making the Puzzle
Step 1. Cut out the edges of the puzzle
If the photograph is smaller than the backing material, start by eliminating the excess edges. If you are using cardboard, use scissors or place the puzzle on a cutting mat and use a utility knife. If the support is made of wood, then cut out the perimeter with the hacksaw, so that it is exactly the same size as the image.
If you are using a hacksaw, place most of the puzzle on a solid, flat surface (such as a table) so that the part to be cut protrudes from the edge. Hold the puzzle with one hand while you tinker with the hacksaw with the other
Step 2. Make a grid
Flip the puzzle over so that the image is facing down. Trace and make a grid by crossing lines so that the whole image is divided into squares of 1.8cm side (for puzzles with small pieces) or 2.5cm (for puzzles with a few large pieces).
Instead of designing the grid yourself, you can print one from the internet by doing a simple online search. This site in English, for example, allows you to download schematics
Step 3. Draw the pattern of the puzzle pieces
To make the various pieces, add spherical protuberances and their reciprocal concave housing along the edges of the grid, so that the various tiles can fit together when they are cut out. You can also use triangular, square, or other shaped bumps and housings.
If you have decided to use a template downloaded from the internet, you will first need to glue it to the back of the puzzle and wait for it to dry
Step 4. Cut out the pieces
If the backing material is cardstock, follow the edges of the template you drew on the back and cut out each tile. Alternatively, you can use a utility knife after placing the puzzle face down on a cutting mat. Always proceed with caution. If the backing material is wood, then you will need a hacksaw, but be careful not to cut yourself. Finally, erase the pencil marks using an eraser.
- To make the process easier, don't cut each tile individually. Instead, try to proceed in rows or columns and then move on to individual pieces.
- The lacquer protects the image from potential damage during the cutting phase, which is especially important when using a hacksaw.
Advice
- Be creative when choosing the puzzle image! You can make this puzzle with whatever you like.
- The puzzle can be in any shape you like: the more experienced craftsmen and carpenters can also give the puzzle the same shape as the picture (for example a puzzle with a picture of a clown can be in the shape of a clown).
Warnings
- Parents must be present for little puzzle creators; children should also not cut anything without the supervision of a responsible adult.
- Always be very careful and wear protective gear when using cutting tools or jigsaws. Take all security measures to protect yourself and others. Never put your fingers in front of a blade.
- If you don't have the skills or experience to carve out a puzzle, ask a skilled person for some advice.
