For our Fabrication class, we had to use the variety of techniques to mass production. The point of this exercise was saving time and to gain consistency as well. Hence we could identify the redundancy of construction so that we could improve the quality of a final product.
I decided to attempt a wooden puzzle consists of same 6 pieces and I found a sketch plan of burr star puzzle from Steve French’s blog. He provided a great basic tutorial for making this one.
I started by searching apt materials at ITP shop, and I luckily got a 1″ depth lumber board in a dumpster. It was a pine board which has a fine condition I think.
I forgot to take a photo before I cut my whole board..
I printed out scaled plan for my 1″ thick puzzle and stuck it on the board directly by an adhesive spray.
Now the most important step has begun. As Steve mentioned in his tutorial post, measuring and cutting the material by accurate 45º is the key to make this puzzle. It was a very certain moment that I need an assistance zig for this.
I couldn’t find a protractor at the shop, so I just used a triangle ruler and drew a 45º line on another board by the hypotenuse. Also, I did not cut off inessential part in advance because I thought that would be dangerous if I try to manage 1″ square stick with power tools. I mainly used a band saw trough whole process and it was easy to use and I could get quite shipshape output from that.
The band saw was wobbling sometimes, but it was enough to make a clean cut on fixed board that against of the zig.
I cut off whole valleys and finally got 6 pieces of fractions.
I tried to use a sander, however, it literally erased parts in a blink, so I smoothly polished all pieces with sandpaper.
It could be assembled simply and I am happy with the puzzle I’ve made.