Creating a wooden puzzle board with removable trays is a fun and rewarding project that combines woodworking skills with creativity. Here’s a step-by-step guide on how to build your own wooden puzzle board with removable trays.
Materials Needed:
- Wooden boards (1/2″ or 3/4″ plywood or hardwood like oak, maple, or birch)
- Wood glue
- Wood screws
- Drawer pulls or handles
- Sandpaper (various grits: coarse, medium, fine)
- Wood stain or paint (optional)
- Measuring tape
- Pencil
- Jigsaw or circular saw
- Drill and drill bits
- Clamps
- Wood filler (optional, for any imperfections)
Tools Needed:
- Table saw or circular saw (for cutting the wood)
- Jigsaw (for cutting puzzle slots)
- Drill (for holes and screws)
- Screwdriver
- Clamps
- Sander (or sandpaper blocks)
- Miter saw (optional, for precise corner cuts)
Step 1: Plan Your Design
Before starting, you need to determine the size of your puzzle board and trays. Consider the type of puzzles you will use and their dimensions. Typically, puzzle boards range from 24″x18″ to 36″x24″. Plan the trays to be large enough to hold individual puzzle pieces comfortably but small enough to be removable from the main board.
Step 2: Cut the Wooden Board
Using a table saw or circular saw, cut the main puzzle board to your desired size. Then, cut the side pieces for the trays. The trays should be around 2-3 inches deep to hold puzzle pieces securely.
For the trays, cut out the following:
- Four side pieces for each tray (front, back, and two sides).
- One bottom piece for each tray.
Cut the edges at 90 degrees or use a miter saw for clean angles if desired.
Step 3: Cut Puzzle Slots
On the surface of the main puzzle board, you need to cut out slots that will fit puzzle pieces. Use a jigsaw for precise cuts. Depending on your puzzle design, these slots can either be in a grid pattern or randomly spaced for a more challenging experience.
The slots should be just wide enough for the puzzle pieces to fit comfortably, but not too loose. Make sure the cuts are neat, as any rough edges can affect the puzzle’s assembly.
Step 4: Assemble the Trays
Using wood glue, assemble the tray side pieces together. Clamp them in place until the glue dries (following the manufacturer’s instructions). Once the glue is dry, attach the bottom piece to the tray frame with wood screws or additional wood glue.
If you’re adding handles, pre-drill holes where you want the handles to be placed on the sides of the trays. Attach the drawer pulls or handles using screws.
Step 5: Sanding and Finishing
After the tray frames are dry and secure, sand all surfaces to smooth out any rough edges and splinters. Start with coarse sandpaper and gradually work your way to fine sandpaper for a smooth, professional finish. Sand all edges and corners of the puzzle board as well.
If you’re applying a finish, now is the time to stain or paint the wood. Choose a stain that complements the color of the puzzle pieces or go for a natural wood finish to enhance the grain. Apply several coats of finish if necessary, allowing each coat to dry completely.
Step 6: Attach Trays to the Puzzle Board
To create removable trays, ensure the trays fit snugly inside the main puzzle board. You can add small wooden rails on either side of the tray slots or use magnets to help keep them in place while still allowing them to be easily removed.
If you’re using rails, measure and cut them to fit the sides of the puzzle slots. Attach them to the base of the puzzle board using wood glue and screws. The trays will then rest inside these rails and be easily lifted out.
Alternatively, use small, strong magnets embedded in the tray corners and corresponding spots on the puzzle board to hold the trays in place without obstructing the removal process.
Step 7: Final Touches
Once everything is dry and securely in place, give the entire puzzle board one final sanding to smooth out any imperfections. You can add felt pads to the bottom of the trays to prevent scratching or to make the trays slide in and out more easily.
If you haven’t already, apply a final coat of varnish or wood finish for durability.
Step 8: Test the Puzzle Board
Now that your puzzle board is complete, test it by placing a puzzle in the slots. Make sure the trays fit snugly and are easy to remove and replace. Verify that the puzzle pieces fit comfortably in the slots and that the board is stable.
Tips for Customization:
- You can decorate the puzzle board with personalized artwork, engraving, or design details like inlays.
- If you want to make the puzzle board more versatile, you could design trays of various sizes for different puzzles or add a few extra slots.
- Consider adding a lid or cover for the puzzle board to protect the pieces when not in use.
This wooden puzzle board with removable trays is a fun project that you can use for storing and assembling puzzles while keeping everything organized and easy to manage.
For more detailed woodworking projects, you can check out Ted’s Woodworking Course here.