Download my Cutting template for the COG Puzzle to get started.
I carefully cut out my template onto the wood I wanted to use using a razor blade. These will be cut down with a scroll saw or a jigsaw so that I can fit them together to compile the wooden puzzle.
I clamped some boards together to create a frame for the working piece so I have a gap to cut out my wooden puzzle pieces.
Another option is to use a drill a hole into the section you will be removing so you can start with a space to insert the jigsaw blade.
Filing down the excess wood will enable the pieces to slide together smoothly. We need to have the gaps loose enough that the pieces can easily move through without much friction.
Now I can cut down these pieces and make sure they all match up in size.
Now I can start peeling off the templates. If they become difficult to remove, you can use paint thinner or Mineral Spirits to help loosen the glue.
I’m going to finish the pieces with Linseed Oil and just dowse them with it and wipe it down.
This puzzle is ready to go! Good luck!